Abstract: An anode casing having a bright tin or bright tin alloy surface layer at least on an inside surface of the casing, preferably on the entire surface of the anode casing, and to an electrochemical cell containing the anode casing. Methods for preparing anode casings and electrochemical cells containing the anode casings are disclosed. In a preferred embodiment, the anode casings are plated at high current density utilizing a variable contact rack plating process, wherein portions of a clamp assembly of the device variably or alternately contact different portions of the anode casing so the entire surface of the anode casing is plated. The bright tin-plated surface is a high hydrogen-overvoltage metal that reduces gassing in cells using the casings.

Abstract: An alkaline electrochemical cell is provided which employs a polymeric moisture barrier material disposed in the collector assembly to substantially prevent the passage of moisture into the cell. The polymeric vapor barrier material may include a polyvinylidene chloride applied to the outer cover, the inner neutral cover, or the top side of the seal, to prevent the ingress and egress of moisture. The polyvinylidene chloride may be applied as a preformed thin sheet. The polymeric material exhibits a very low water vapor transmission rate of less than 1.0 (grams×mil)/(100 inches2×day) at 100° F. and 100 percent RH.

Abstract: An electrochemical cell is provided having a non-cylindrical container including one or more side walls each having a curved surface that curves radially inward. The electrochemical cell further includes first and second electrodes and a separator disposed therebetween. A cover and seal assembly is assembled to the top open end of the container. The radially inwardly curved surface of the side walls opposes forces caused by internal pressure within the cell so as to reduce and/or prevent bulging of the side walls.

Abstract: An electrochemical cell is provided having a non-cylindrical container including one or more side walls each having a curved surface that curves radially inward. The electrochemical cell further includes first and second electrodes and a separator disposed therebetween. A cover and seal assembly is assembled to the top open end of the container. The radially inwardly curved surface of the side walls opposes forces caused by internal pressure within the cell so as to reduce and/or prevent bulging of the side walls.

Abstract: Assembly of an electrochemical cell using a prismatic steel can having an enlarged circular opening at one end. The active materials of this cell including the cathode are disposed into the prismatic can through the circular opening, and the circular opening is subsequently reduced in size to a round reduced size opening. A round cover and seal assembly closes the opening of the cell.

Abstract: An electrochemical cell, such as an alkaline cell, employing a multi-strip separator formed into a closed end cylindrical configuration and where an electrically insulating barrier, such as a plastic film, is disposed at the bottom surface of the separator to prevent electrical shorting between the electrodes of the cell at this location.