Abstract: A method of forming a nickel layer on a metal substrate forming the terminal contact area of the cathode casing for a zinc-air cell. A cathode casing in desired shape and size for a zinc-air cell is formed of a substrate metal such as cold rolled steel or stainless steel. A nickel layer is plated onto the cathode casing substrate metal over the terminal contact area and is subsequently heat treated resulting in reduction in the surface hardness. The method of heat treatment involves heating the substrate metal with nickel plated thereon in an inert atmosphere at temperatures preferably between about 860° F. and 135° F. The method reduces the nickel surface hardness to a level below 8 GPa. This improves the electrical contact with the hearing aid or other device being powered.

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 zinc/air depolarized button cell having an anode casing and cathode casing in the form of cans each having an open end and opposing closed end with integral side walls therebetween. An improved insulator seal ring is inserted over the anode casing side walls. The improved insulator seal ring has protrusions emanating from the surfaces of the insulating ring side walls. The protrusions are preferably integrally formed during molding of the insulating seal ring, but may be separately applied. The protrusions compress during application of radial forces to the cathode casing during the crimping of the cathode casing side walls over the anode casing side walls with said insulator ring therebetween. This provides a tighter, more durable seal, at the interface between anode casing and insulator side walls and also between cathode casing and insulator side walls.

Abstract: A zinc-air cell with an anode cup comprising anode active material and a cathode cup comprising catalytic or cathode active material wherein the cathode cup comprises an exposed nickel layer which has been softened to improve electrical contact with the device being powered such as a hearing aid. A cathode cup in desired shape and size is formed of a substrate metal such as cold rolled steel or stainless steel. A nickel layer is plated onto the cathode cup substrate metal and is subsequently heat treated resulting in reduction in the surface hardness of the nickel layer. This improves the reliability of the electrical contact between the cathode cup and the corresponding terminal in the hearing aid or other device being powered.

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: An anti-siphoning device that can be installed without special tools and/or modification to a storage tank inlet. A cylindrical insert has holes in a bottom and side that allow liquid to pass to a storage tank while preventing the insertion of a siphoning hose into the tank. The insert has rings affixed to an outer wall that frictionally engage inner walls of the tank inlet to prevent withdrawal of the insert.