Abstract: An alkaline battery can include a housing, a cathode within the housing, an anode, a separator between the anode and the cathode, and an alkaline electrolyte contacting the anode and the cathode. The cathode defines an anode cavity and the anode is deposited within the anode cavity. The cathode has a top surface adjacent to the anode cavity. The battery can include a protective layer deposited on the top surface of the cathode and/or a gel plug deposited over the anode. The protective layer can include a PVA layer coated over the top surface of the cathode.

Abstract: An alkaline cell with improved separator. The separator is formed of two sheets. The two sheets are wound into a tube shape and the bottom edge of the wound separator is folded and heat sealed. The facing surfaces of the two sheets forming the separator body are not glued or bonded together. The two separator sheets may overlap laterally so that a portion of each sheet forms a different portion of the separator outside surface. Alternatively, the separator may be formed of two sheets wherein the first sheet forms an outer layer which completely covers the second sheet. One sheet is preferably composed of a blend of polyvinylalcohol fibers and rayon fibers and the other sheet composed of polyvinylalcohol fibers and wood pulp fibers.

Abstract: An alkaline battery can include a housing, a cathode within the housing, an anode, a separator between the anode and the cathode, and an alkaline electrolyte contacting the anode and the cathode. The cathode defines an anode cavity and the anode is deposited within the anode cavity. The cathode has a top surface adjacent to the anode cavity. The battery can include a protective layer deposited on the top surface of the cathode and/or a gel plug deposited over the anode. The protective layer can include a PVA layer coated over the top surface of the cathode.

Abstract: A method of applying liquid adhesive to surfaces of components of an electrochemical cell employing a needle valve applicator. The liquid adhesive is applied by dispensing it through a tubular tip connected to a pneumatically actuated needle valve applicator. The method is effective in applying adhesive to narrow width or difficult to reach surfaces of cell components in a precise, consistent and reproducible manner. In a specific application the adhesive can be applied to the narrow recessed step surrounding the terminal portion of the cathode casing of a zinc/air button cell. In such application the cathode casing may typically be rotated at speeds of between about 50 and 1000 revolutions per minute as adhesive is applied thereto from the applicator. The adhesive provides a tight seal between the cathode casing and cathode assembly, thereby preventing leakage of electrolyte from the cell.

Abstract: A spray method of applying liquid adhesive to surfaces of components of an electrochemical cell. The adhesive is applied by spraying through a nozzle, preferably activated by a piezoelectric transducer. The nozzle can be an elongated resilient tube terminating in an outlet opening. The adhesive is preferably sprayed in a pulsed stream of droplets. The liquid adhesive is desirably dispensed in fine droplets at a rate of between about 500 and 5000 droplets per second. The method is effective in applying adhesive to narrow width or difficult to reach surfaces of cell components in a precise, consistent and reproducible manner. In a specific application the adhesive can be applied to the narrow recessed step surrounding the terminal portion of the cathode casing of a zinc/air button cell. In such application the adhesive provides a tight seal between the cathode casing and cathode assembly, thereby preventing leakage of electrolyte from the cell.

Abstract: A porous product, typically a foam sheet, can be produced by peeling of a foam supply. By peeling the foam supply along its z axis, a product is produced having pores with a uniform pore aspect ratio in the longitudinal direction. Such a porous product, when containing an active filler, can be used as a battery electrode. The electrode can have enhanced electrical and mechanical properties.

Abstract: A process is disclosed, as well as apparatus useful therefor, for continuously electroplating a strip of reticulated foam using multiple electroplating zones that each contain electroplating bath. In each zone there is a cathode and an anode. In at least one electroplating zone there is an insoluble anode, typically as the sole anode. In some of the electroplating zones soluble anodes may be used. As a first cathode, there can be provided a cathode roll outside of the electroplating bath. The reticulated foam is guided in the bath past the anodes, as well as past cathodes, e.g., including a cathode roll which may be positioned outside of the bath. The resulting electroplated foam emerging from the bath has an improved electroplate weight distribution and the process achieves enhanced efficiencies and economies of operation.

Abstract: A porous product, typically a metal foam sheet, is produced as a tailored, engineered product. The porous product can have enhanced strength, as well as more desirable electrical and mechanical properties. The product which first exists typically as a flexible, generally polymeric foam sheet in strip form, which strip is produced in the longitudinal direction, is stretched in a direction other than its direction of production. The porous product can have pores which would be anisotropic in form in usual production, which are stretched to at least substantially isotropic form. The product can even be tailored to have pores which are anisotropic in the direction of the stretch. Thus, an engineered product can be produced which, for example, as an open-cell metal foam prepared from a polymeric foam can have conductivity, both thermal and electrical, as well as strength and ductility, tailored for greater uniformity and performance.