Abstract: A separator for an electrochemical cell and a method of assembling an electrochemical cell are provided. The separator includes a porous paper substrate impregnated and/or coated with a polymer solution that coagulates to prevent electrical shorting while allowing ion permeation. The method include the steps of providing a container having a bottom end and a top end and upstanding walls disposed therebetween, disposing positive electrode and negative electrodes in the container, providing a sheet of porous paper substrate, forming the sheet of porous substrate into a separator, applying alkaline solution to the separator, applying a liquid polymer material to the porous substrate in the presence of the alkaline solution so that the polymer solution coagulates to form a semi-solid material, and disposing the separator between the positive electrode and the negative electrode.

Abstract: An electrochemical cell construction having a large anode-to-cathode interfacial surface area to realize improved high rate service performance in an easy-to-manufacture construction. A first electrode, such as the cathode, is formed having a conductive current collector integrally embedded therein. Separator material is disposed on both the inner and outer cylindrical walls of the first electrode. An outer electrochemically active material covers the outer separator material outside of the first electrode and an outer insulation is layered on top of the outer electrochemically active material to form a cathode bobbin. The cathode bobbin is disposed into a container having a closed bottom end and an open top end. A second electrode, such as an anode, is disposed in the inner cylindrical volume formed in the first electrode and a conductive path is provided between the outer electrochemically active material and the second electrode.

Abstract: A battery including a polar solvent transportive, ionically conductive separator formed directly on an electrode is prepared by applying a coating composition containing a polymer or gel dispersed in a polar solvent directly to the electrode surface and solidifying materials in the coating composition to form a separator membrane.

Abstract: An electrochemical cell and an electrode for use in an electrochemical cell is provided. The electrochemical cell has a container, a positive electrode disposed in the container and having a wall defining an interface surface, a negative electrode disposed in the container, a separator located between the positive and negative electrodes, and an electrolyte. The second electrode has a unitary piece of electrochemically active material having multiple openings formed in a circumferential surface. The unitary piece may include a slotted tube, first and second members, or a coiled strip.

Abstract: An adhesive closure for sealing closed the open end of an electrochemical cell container. The electrochemical cell comprises a can having an open end and a side wall, and positive and negative electrodes disposed in the can. The cell also has a cover disposed on the open end of the can and having a peripheral wall radially outside of the side wall of the can. One or more adhesives are disposed between the outer side wall of the can and the peripheral wall of the cover for adhering the cover to the can.

Abstract: An electrochemical cell construction having a large anode-to-cathode interfacial surface area to realize improved high rate service performance in an easy-to-manufacture construction. A first electrode, such as the cathode, is formed having a conductive current collector integrally embedded therein. Separator material is disposed on both the inner and outer cylindrical walls of the first electrode. An outer electrochemically active material covers the outer separator material outside of the first electrode and an outer insulation is layered on top of the outer electrochemically active material to form a cathode bobbin. The cathode bobbin is disposed into a container having a closed bottom end and an open top end. A second electrode, such as an anode, is disposed in the inner cylindrical volume formed in the first electrode and a conductive path is provided between the outer electrochemically active material and the second electrode.

Abstract: An anode degassing process for removing gas and densifying a slurry of anode mix. The process includes the steps of manufacturing an anode mix, aging the anode mix for at least thirty minutes following manufacture of the anode mix, disposing the aged anode mix into a degassing mixer, generating a vacuum in the degassing mixer, and agitating the anode mix by mixing in the presence of the vacuum so as to remove gas from the anode mix. The anode mix achieves a density of greater than 96 percent of the theoretical density.

Abstract: A battery having a hydrogen removing agent disposed on the battery external from the active cell volume of its container for removing hydrogen produced by the electrochemically active materials. The hydrogen removing agent is disposed on a surface of the seal member which is disposed within an open top end of the container, according to one embodiment. According to other embodiments, the hydrogen removing agent is disposed on an inner surface of an outer cover, or disposed on a label on the outside walls of the container. A multi-cell battery is also provided having the hydrogen removing agent disposed on the interior walls thereof.

Abstract: One embodiment of the present invention is a method for synthesizing superabsorbent polyacrylate polymers comprising the steps of providing an acrylate monomer, a multifunctional monomer, and free radical initiator in the absence of a solvent; mixing the acrylate monomer, multifunctional monomer, and free radical initiator to create a solvent free solution; and subjecting the solvent free solution to radiation to create a cross-linked polymer. The product created by this method is also a part of the present invention.

Abstract: A battery comprising a steel can having a bottom end, an open top end, and side walls extending between the top and bottom ends. Positive and negative electrodes are disposed in the can. An outer cover is disposed over the open end of the can. The outer cover has an outer flange disposed on the outside of the can walls and an inner flange disposed on the inside of the can wall. A seal is disposed between the can and the outer cover so that the seal is disposed against the inner and outer flanges of the outer cover. The outer cover is preferably crimped against the can wall to compress the seal between the inner and outer flanges and the container, thereby minimizing axial loading on the can and allowing for use of a thin gauge can.

Abstract: An electrochemical cell is provided that comprises an anode comprising a zinc alloy active material and elemental sulfur. Also provided is a method of making an electrochemical cell comprising the steps of providing a cathode, an electrolyte, and an anode, adding elemental sulfur to the anode, and putting the anode and cathode in contact with the electrolyte.