Abstract: The electrode structure includes a cathode, anode and polymeric separator, wound into an oval configuration having a length and width equal to interior dimensions of the rectangular housing. The oval shape is achieved by winding a long, flat electrode structure around a mandrel. The length of the electrode structure is chosen based upon the size of the mandrel, the interior dimensions of the housing, and the width of the electrode structure, such that, after winding, the resulting oval structure snugly fits within the rectangular housing leaving no remaining spaces, other than in corners of the housing. A leaf spring is provided between a free end of the electrode structure and an interior wall of the housing for ensuring that the electrode structure remains tightly wound. Appropriate electrical contacts are provided to the anode and cathode of the electrode structure.

Abstract: The electrochemical cell includes an electrode structure having an aluminum current collector in combination with an active cathode material containing polycarbon monofluoride. The electrode structure also includes a polymeric separator and a lithium anode. The electrode structure is spiral wound and mounted within a cylindrical housing formed of conventional stainless steel. Care is taken to ensure that the aluminum foil isolates the polycarbon monoflouride of the cathode material from the stainless steel of the housing. The cylindrical housing is flooded with a non-aqueous electrolyte solution. The resulting cell is employed within an implantable medical device. In an alternative embodiment, electrode structures employing the aluminum current collector and the polycarbon monoflouride active cathode material are formed as rectangular plates and are mounted in parallel within a rectangular housing. In another alternative embodiment, the aluminum current collector is employed within a button cell.

Abstract: An expanded screen current collector is provided with side edges coined inwardly to prevent sharp tines formed along the side edges from damaging adjacent components within the electrochemical cell. The expanded screen current collector is formed by cutting a thin flat sheet of current collector material, such as titanium or stainless steel, to have a height somewhat greater than a height required for use within the electrochemical cell. The current collector material is cut and expanded, then the side edges are coined inwardly by an amount sufficient to reduce the height of the resulting expanded screen current collector to a height appropriate for use within the electrochemical cell. An active cathode material, such as polycarbonmonoflouride, is coated onto side surfaces of the expanded screen current collector. An electrode structure employing the expanded screen current collector having the coined edges is also described.

Abstract: A cathode material is fabricated using two binder compounds, polyethylene oxide and acrylic resin, which react during processing to achieve enhanced bonding. The cathode material is formed by dissolving acrylonitril resin within the acetonitrile solvent. Polyethylene oxide powder is added yielding a homogenous solution. A powder mix containing a carbon material, such as high surface area carbon powder, and an active cathode compound, such as polycarbon monoflouride, is added to the binder mixture to produce a slurry. In one embodiment, the slurry is heated to evaporate the solvents, yielding a thin flexible cathode material for mounting to an expanded screen current collector. In an alternative embodiment, the slurry is spread directly onto a foil current collector. The solvents thereafter evaporate from the slurry yielding excellent mechanical and electrical coupling between the active cathode compound and the current collector.