Abstract: An electrochemical cell has a cell housing and an electrode assembly disposed in the housing. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator. An end of each of the positive and negative electrode plates includes a clear lane that is free of active material and includes an opening. An electrically conductive first inner plate extends through the openings in each positive electrode plate, and an electrically conductive second inner plate extends through openings in each negative electrode plate. The positive clear lanes are sandwiched between, and electrically connected to, the first inner plate and a first outer plate. The negative clear lanes are sandwiched between, and electrically connected to, the second inner plate and a second outer plate. The first outer plate is electrically connected to the housing, and the second outer plate is electrically connected to a terminal.

Abstract: An electrochemical cell has a prismatic cell housing and an electrode assembly disposed in the cell housing. The cell housing is six-sided and includes a first end, a second end, and a sidewall that extends between the first and second ends. The sidewall includes a pair of major sides joined by a pair of minor sides, where each side of the pair of major sides is larger in area than each side of the pair of minor sides. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator to form an electrode stack. The electrode stack is oriented within the cell housing such that a stack axis that extends parallel to a stacking direction of the positive and negative electrode plates is normal to, and passes through, each side of the pair of minor sides.

Abstract: A method of manufacturing an electrochemical cell is provided. The cell includes a rigid housing and an electrode assembly disposed in the housing. The method includes providing a housing that includes a first end, a second end formed separately from the first end, and a tubular sidewall formed separately from each of the first end and the second end. After the electrode assembly is inserted into the sidewall, the first end is welded to one end of the sidewall, and the second end is welded to the other end of the sidewall.

Abstract: An electrochemical cell has a cell housing and an electrode assembly disposed in the housing. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator. An end of each of the positive and negative electrode plates includes a clear lane that is free of active material and includes an opening. An electrically conductive first inner plate extends through the openings in each positive electrode plate, and an electrically conductive second inner plate extends through openings in each negative electrode plate. The positive clear lanes are sandwiched between, and electrically connected to, the first inner plate and a first outer plate. The negative clear lanes are sandwiched between, and electrically connected to, the second inner plate and a second outer plate. The first outer plate is electrically connected to the housing, and the second outer plate is electrically connected to a terminal.

Abstract: A method of manufacturing an electrochemical cell is provided. The cell includes a rigid housing and an electrode assembly disposed in the housing. The method includes providing a housing that includes a first end, a second end formed separately from the first end, and a tubular sidewall formed separately from each of the first end and the second end. After the electrode assembly is inserted into the sidewall, the first end is welded to one end of the sidewall, and the second end is welded to the other end of the sidewall.

Abstract: An electrochemical cell has a prismatic cell housing and an electrode assembly disposed in the cell housing. The cell housing is six-sided and includes a first end, a second end, and a sidewall that extends between the first and second ends. The sidewall includes a pair of major sides joined by a pair of minor sides, where each side of the pair of major sides is larger in area than each side of the pair of minor sides. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator to form an electrode stack. The electrode stack is oriented within the cell housing such that a stack axis that extends parallel to a stacking direction of the positive and negative electrode plates is normal to, and passes through, each side of the pair of minor sides.

Abstract: An improved method of gas metal arc welding (GMAW) utilizing relatively low current levels. The method includes providing a variable current to form and detach a droplet from a consumable wire electrode. During the welding process, the current is sufficient to produce a droplet at the end of a consumable electrode wire, but not to independently detach the droplet. After the droplet reaches a desired diameter, the current is lowered to induce an oscillation in the droplet. At a selected oscillation of the droplet, the current is increased. The combination of the momentum created by the oscillation of the droplet and the electromagnetic force caused by the increased current serves to detach the droplet from the electrode wire.

Abstract: An improved method of gas metal arc welding (GMAW) is disclosed. The method includes utilizing a pulsed current having a variable waveform to ensure the detachment of one-droplet-per-pulse of current. During the welding process, the current is sufficient to produce a droplet at the end of a consumable electrode wire. After the droplet reaches a desired size, the current is lowered to induce an oscillation in the droplet. The current is then increased which, in combination with the momentum created by the oscillation, effects droplet detachment. The oscillation may be monitored by observing the arc voltage to determine a preferred detachment instant. A computer implemented method allows for the adaptive control of the current waveform to accommodate for anticipatable variations in the welding conditions, while maintaining ODPP transfer and a constant pulse period. An accompanying system is disclosed for implementing the method of adaptive welding.