Abstract: A current collector in the form of a conductive substrate subjected to a special chemical etch to provide the current collector having a multi-thickness structure, is described. The multiple-thickness current collector structure provides an electrochemical cell with increased charge capacity per volume while enabling a robust weld connection thereto. The current collector has a frame and comprises within an inner perimeter of the frame, first strand structures that intersect second strand structures to provide a plurality of openings or interstices bordered by the strands. At least one tab portion having a thicker distal portion spaced from a thinner proximal tab portion that extends from an outer perimeter of the frame.

Abstract: A current collector in the form of a conductive substrate subjected to a special chemical etch to provide the current collector having a multi-thickness structure, is described. The multiple-thickness current collector structure provides an electrochemical cell with increased charge capacity per volume while enabling a robust weld connection thereto. The current collector has a frame and comprises within an inner perimeter of the frame, first strand structures that intersect second strand structures to provide a plurality of openings or interstices bordered by the strands. At least one tab portion having a thicker distal portion spaced from a thinner proximal tab portion that extends from an outer perimeter of the frame.

Abstract: A current collector in the form of a conductive substrate subjected to a special chemical etch to provide the current collector having a multi-thickness structure, is described. The multiple-thickness current collector structure provides an electrochemical cell with increased charge capacity per volume while enabling a robust weld connection thereto. The current collector has a frame and comprises within an inner perimeter of the frame, first strand structures that intersect second strand structures to provide a plurality of openings or interstices bordered by the strands. At least one tab portion having a thicker distal portion spaced from a thinner proximal tab portion that extends from an outer perimeter of the frame.

Abstract: A method for making an electrochemical device enclosure is described. The methods comprises the steps of forming first and second casing members; inserting electrochemically active materials within the first casing member; mating the first casing member to the second casing member, thereby forming an interface therebetween; providing a laser welding apparatus comprising a laser; intermittently turning a laser beam on and off while traversing the laser in a first welding pass 360 degrees along the perimeters of the first and second casing members, thereby forming a first intermittent set of welded and unwelded sections at the interface between the casing members; and intermittently turning the laser beam on and off while traversing the laser in a second welding pass 360 degrees along the perimeters of the first and second casing members, thereby forming a second intermittent set of welded sections at the interface between the first and second casing members.

Abstract: A method for making an electrochemical device enclosure is described. The methods comprises the steps of forming first and second casing members; inserting electrochemically active materials within the first casing member; mating the first casing member to the second casing member, thereby forming an interface therebetween; providing a laser welding apparatus comprising a laser; intermittently turning a laser beam on and off while traversing the laser in a first welding pass 360 degrees along the perimeters of the first and second casing members, thereby forming a first intermittent set of welded and unwelded sections at the interface between the casing members; and intermittently turning the laser beam on and off while traversing the laser in a second welding pass 360 degrees along the perimeters of the first and second casing members, thereby forming a second intermittent set of welded sections at the interface between the first and second casing members.

Abstract: An electrochemical cell comprising a conductive casing housing an electrode assembly provided with a stack holder surrounding the electrode assembly is described. The stack holder is of an elastic material that serves to maintain the anode and cathode in a face-to-face alignment throughout discharge. This is particularly important in later stages of cell life. As the cell discharges, anode active material is physically moved from the anode to intercalate with the cathode active material. As this mass transfer occurs, the cathode becomes physically larger and the anode smaller. This can lead to misalignment. However, the stack holder prevents such misalignment by maintaining a constrictive force on the electrode assembly throughout discharge.

Abstract: An alkali metal/solid cathode electrochemical cell, such as of a Li/SVO couple, having the cathode material supported on a titanium current collector screen coated with a carbonaceous material is described. The thusly-coated titanium current collector provides the cell with higher rate capability in comparison to cells of a similar chemistry having the cathode active material contacted to an uncoated titanium current collector.

Abstract: An alkali metal/solid cathode electrochemical cell, such as of a Li/SVO couple, having the cathode material supported on a titanium current collector screen coated with a carbonaceous material is described. The thusly-coated titanium current collector provides the cell with higher rate capability in comparison to cells of a similar chemistry having the cathode active material contacted to an uncoated titanium current collector.

Abstract: The present invention provides a means for attaching a thin terminal extension to a glass sealed terminal electrode utilizing the least amount of space and total height. The terminal extension is of sufficient width to allow a hole sized to the diameter of the pin and the pin is received in the opening in the terminal extension. A series of spot welds are made along the perimeter of the pin at the interface with the terminal extension. If necessary, an insulator is placed between the terminal extension and the surface of the battery case to prevent electrical shorting to the case. Hence, the total height of the assembly is the sum of the thickness of the insulator plus the terminal extension. This design can apply to terminations made externally to or internally in the electrochemical cell.