Abstract: A cathode that includes manganese dioxide and relatively small particles of nonsynthetic, nonexpanded graphite is disclosed. The graphite particles can have an average particle size of less than 20 microns. The cathode can be used in an electrochemical cell, such as a battery.

Abstract: An electrochemical cell having a high capacity is described. The cell capacity can be increased by a method of selecting cell components to achieve particular volume ratios within the cell. Specific volume ratios that lead to improved capacity include the ratio of the internal cell volume to the external volume, the ratio of the closure volume to the external volume, the ratio of the closure volume to the internal cell volume, the ratio of the seal volume to the internal cell volume, and the ratio of the seal volume to the external volume.

Abstract: An electrode containing zinc-based particles suspended in a fluid medium is disclosed. The zinc-based particles have a multi-modal distribution, such as a bi-modal distribution, of particle sizes, particle morphologies and/or particle compositions. The electrode can be used as the anode in an alkaline battery, such as a primary alkaline battery.

Abstract: A cathode that includes manganese dioxide and relatively small particles of nonsynthetic, nonexpanded graphite is disclosed. The graphite particles can have an average particle size of less than 20 microns. The cathode can be used in an electrochemical cell, such as a battery.

Abstract: An electrode containing zinc-based particles suspended in a fluid medium is disclosed. The zinc-based particles have a multi-modal distribution, such as a bi-modal distribution, of particle sizes, particle morphologies and/or particle compositions. The electrode can be used as the anode in an alkaline battery, such as a primary alkaline battery.

Abstract: A primary electrochemical cell with an anode comprising zinc alloy particles suspended in a fluid medium is disclosed. The zinc alloy particles include at least about 10 percent, by weight, of fines (particles of −200 mesh size) or dust (particles of −325 mesh size). The zinc particles are preferably alloyed with indium or bismuth and of acicular or flake form. The anode has a low resistivity at low zinc loadings, and the cell demonstrates good mechanical stability and overall performance.

Abstract: A sealed, prismatic electrochemical cell has an electrode plate comprising a porous structure with a maximum linear dimension of the porous structure in the principle direction of ion flow of at least 20 percent of the maximum linear dimension of the housing cavity in the principle direction of ion flow. The cell can produce good current density while having a high capacity. The electrode construction can result in a low diffusion polarization despite the thickness of the electrode. The overall cell can be economically manufactured, and has a low percentage of its internal volume occupied by inactive materials. Electrode plaque constructions and active material compounds are also disclosed.

Abstract: The present invention relates to coiled electrode assemblies having conductive tabs, methods of attaching the conductive tabs to the coiled electrode, and electrochemical cells employing such assemblies. An electrode plate which is coated with active material has a designated area for tab attachment. The conductive tab area's active material is pierced with opposing, offset piercing plates which have raised surface probes which penetrate the conductive tab area's coating and substrate. This tab area is cleared of active material and reinforced with a reinforcing material and a conductive tab is welded to the thus treated area resulting in an electrode plate having a strong integrated tab assembly.

Abstract: A primary electrochemical cell with an anode comprising zinc alloy particles suspended in a fluid medium is disclosed. The zinc alloy particles include at least about 10 percent, by weight, of fines (particles of −200 mesh size) or dust (particles of −325 mesh size). The zinc particles are preferably alloyed with indium or bismuth and of acicular or flake form. The anode has a low resistivity at low zinc loadings, and the cell demonstrates good mechanical stability and overall performance.

Abstract: The present invention relates to coiled electrode assemblies having conductive tabs, methods of attaching the conductive tabs to the coiled electrode, and electrochemical cells employing such assemblies. An electrode plate which is coated with active material has a designated area for tab attachment. The conductive tab area's active material is pierced with opposing, offset piercing plates which have raised surface probes which penetrate the conductive tab area's coating and substrate. This tab area is cleared of active material and reinforced with a reinforcing material and a conductive tab is welded to the thus treated area resulting in an electrode plate having a strong integrated tab assembly.

Abstract: An alkaline cell is disclosed having a cathode comprising manganese dioxide wherein the cathode is a semisolid during discharge of the cell. The cell has an anode comprising zinc and an electrolyte comprising potassium hydroxide. The semisolid cathode comprising manganese dioxide may be in the form of a putty or paste. The semisolid cathode reduces cathode polarization effects and results in increased manganese dioxide utilization (Amp-hr/g), particularly at high current drain, between about 0.5 and 2 Amp. The porosity of the cathode is between about 45% and 70%, and the volume ratio of electrolyte solution in the cathode to the solids in the cathode is at a value between about 0.7 and 2.3.

Abstract: A hydrogen storage alloy of the AB5-type, where the A component includes La and/or Nd and at least 0.4 mole fraction Pr, as well as batteries including the alloy, are disclosed.

Abstract: A thin separator for batteries is provided. The separator includes a layer that reduces dendrite shorting and a nonwoven layer. Typically, the separator also includes a laminate layer disposed between the nonwoven layer and the layer which reduces dendrite shorting. Additional nonwoven layers can also be included in the separator.

Abstract: An end cap assembly for an electrochemical cell, for example an alkaline cell, is disclosed comprising an exposed terminal end cap of single piece construction having a convoluted surface, an electrically insulating member and a metal support disk between the insulating member and the terminal end cap. The end cap assembly is inserted into the open end of the cell housing after the cell contents have been supplied. A portion of the end cap surface is a flat annular step which improves contact between the end cap and the electrically conductive portion of a condition tester for the cell which may be integrated into the cell label. The annular step is advantageously located at about right angle to the cell's longitudinal axis. The surface step is integral with the end cap and preferably located at about the same level as the shoulder of the cell housing at the end of the cell containing the end cap. The end cap assembly as a whole provides a tight seal for the cell.

Abstract: A cathode that includes manganese dioxide and a titanium oxy salt, preferably titanium oxy sulfate, is disclosed.

Abstract: An end cap seal assembly for an electrochemical cell such as an alkaline cell is disclosed. The end cap assembly comprises a convoluted end cap disk which may also function as a cell terminal and an underlying insulating disk also having a convoluted surface. The convoluted end cap disk has a downwardly extending wall with at least one aperture therethrough which preferably faces the ambient environment. The insulating disk has a downwardly extending wall forming a rupturable membrane which underlies and abuts the inside surface of the downwardly extending wall of the end cap. The rupturable membrane underlies and abuts the aperture in the downwardly extending wall of the end cap. When gas pressure within the cell exceeds a predetermined level the rupturable membrane pushes through said aperture and ruptures allowing gas to escape therefrom directly to the environment. A separate terminal plate may be welded to a portion of the top surface of the convoluted end cap.

Abstract: The invention is directed to a method of forming a pip protrusion at the closed end of a cylindrical casing of an electrochemical cell. The cell is preferably an alkaline cell having an anode comprising zinc, a cathode comprising manganese dioxide, and an alkaline electrolyte. The method of the invention is directed to forming the pip protrusion at the closed end of the casing so that the pip protrusion becomes an integral part of the casing. In an alkaline cell the pip protrusion becomes the cell's positive terminal. The method of the invention involves inserting cathode material into the casing through the open end thereof and then forcing an elongated plunger having a diameter less than the inside diameter of casing into the cathode material while providing means for preventing the cathode material form rising more than a predetermined level with the casing.

Abstract: A current interrupt assembly for electrochemical cells is disclosed. The current interrupter assembly may be a self-contained, sealed unit which may be separately inserted into the cell during cell construction. Several current interrupt assemblies may be inserted in the cell. The current interrupter assembly has particular utility for thin rechargeable cells and when inserted in the cell forms a portion of the electrical pathway between a cell electrode and corresponding terminal. The current interrupt mechanism comprises a thin thermally responsive member preferably comprising a disk of a shape memory metal alloy having a curved surface. When cell temperature exceeds a predetermined value the disk deflects to cause a break in the electrical pathway within the assembly. The assembly may include therein a flexible electrically conductive member which forms a part of the electrical pathway within the assembly and which is physically responsive to deflection of the thermally responsive member.

Abstract: The invention is directed to a pressure activated current interrupt assembly for cells, particularly alkaline cells. The current interrupter is located at the closed end of the cell's housing. The current interrupter assembly comprises an electrically insulating member in proximity to the terminal at the closed end of the housing. The insulating member is in physical communication with a deflectable member formed from the cell's housing. When gas pressure within the cell builds up to exceed a predetermined value, the deflectable member deforms causing the insulating member to protrude beyond the extremity of said cell terminal, thereby preventing electrical contact between said terminal and the terminal of another cell or electrical device.

Abstract: An AB.sub.5 -type hydrogen absorbing alloy composition for use in an electrochemical cell includes between about 0.001 and 0.01 mole percent of zirconium and/or titanium dispersed throughout the alloy. Methods of producing the alloy are also disclosed. The levels of these elements have been selected to maintain low hydrogen equilibrium pressure, high capacity, and acceptable activation characteristics, along with improved storage characteristics and improved cycle life from reduced corrosion.