Abstract: A seal assembly for a battery cell includes a grommet having an opening having an inner surface. A nail has a nail head and a stem extending from the stem. The stem includes a first portion with a larger diameter and a second portion with a smaller diameter and the stem extends through the opening in the grommet. The stem and the grommet form a first interference fit at a distal end of the opening. A trap clearance is formed between the distal end of the opening and the nail head. The trap clearance defines a trap for a sealant. A sealant is disposed on the stem and is located at least partially in the trap.

Abstract: A seal assembly for a battery cell includes a grommet having an opening having an inner surface. A nail has a nail head and a stem extending from the stem. The stem includes a first portion with a larger diameter and a second portion with a smaller diameter and the stem extends through the opening in the grommet. The stem and the grommet form a first interference fit at a distal end of the opening. A trap clearance is formed between the distal end of the opening and the nail head. The trap clearance defines a trap for a sealant. A sealant is disposed on the stem and is located at least partially in the trap.

Abstract: A seal assembly for a battery cell includes a grommet having an opening having an inner surface. A nail has a nail head and a stem extending from the stem. The stem includes a first portion with a larger diameter and a second portion with a smaller diameter and the stem extends through the opening in the grommet. The stem and the grommet form a first interference fit at a distal end of the opening. A trap clearance is formed between the distal end of the opening and the nail head. The trap clearance defines a trap for a sealant. A sealant is disposed on the stem and is located at least partially in the trap.

Abstract: Batteries having vents are disclosed. An example battery includes a housing, including: a first terminal and a second terminal. The first terminal includes a cover. The cover includes at least one line of weakness therein. The line of weakness is structured to form an opening when a threshold pressure is satisfied within the housing to enable gas to vent from the housing through the opening. A filter is positioned within the housing and adjacent the cover. The filter has an aperture structured to enable the gas to vent from the housing and to deter solid material housed within the housing from exiting the opening when the threshold pressure is satisfied.

Abstract: Batteries having vents are disclosed. An example battery includes a housing, including: a first terminal and a second terminal. The first terminal includes a cover. The cover includes at least one line of weakness therein. The line of weakness is structured to form an opening when a threshold pressure is satisfied within the housing to enable gas to vent from the housing through the opening. A filter is positioned within the housing and adjacent the cover. The filter has an aperture structured to enable the gas to vent from the housing and to deter solid material housed within the housing from exiting the opening when the threshold pressure is satisfied.

Abstract: An end cap assembly for an electrochemical cell having an end cap, a current collector, and a seal. The end cap has a top surface and a bottom surface. The current collector has a columnar body with a head at one end thereof. The seal has a central boss with an opening through which the current collector is inserted. The seal also has a peripheral edge and a connecting part connecting the central boss with the peripheral edge. The connecting part of the seal has a top surface and a bottom surface. The central boss has a top surface and a bottom surface. The top surface of the central boss faces the bottom surface of the end cap and the bottom surface of the central boss does not extend below the bottom surface of the connecting part. The current collector is positioned within the opening of the central boss so that the head of the current collector does not touch the top surface of the central boss thus forming a gap from about 0.01 mm to about 0.

Abstract: Battery cartridges are disclosed that include a housing having a plurality of air access openings configured to selectively control flow of air into the housing; and at least two adjacent metal-air electrochemical cells within the housing, each electrochemical cell having an outer gas permeable barrier membrane layer that defines the exterior surface of the electrochemical cell; wherein there is a gap between adjacent electrochemical cells in the housing and wherein the air access openings in the housing are positioned over or partially overlapping each gap.

Abstract: A non-hermetically sealed, electrochemical power source, includes a first electrode, a second electrode, a separator between the first electrode and the second electrode, and a membrane in fluid communication with an environment external to the battery. The second electrode is between the separator and the membrane. The membrane includes a first portion having a different property, e.g., density, porosity, mass transport resistance, thickness, or gas permeability, than a second portion of the membrane. Methods of designing an electrochemical cell cartridge are also disclosed.

Abstract: A battery includes a cathode having an interior surface and an exterior surface, and defining a cavity and two open ends; a separator disposed adjacent to the interior surface of the cathode; an anode disposed adjacent to the separator and inside the cavity; an air-permeable, liquid-impermeable barrier layer disposed adjacent to the exterior surface of the cathode, and defining an exterior surface of the battery; two end members connected to the open ends of the cathode; and an anode current collector extending through the two end members. Methods designed such a battery is also disclosed.

Abstract: And end cap assembly and venting system therein for closing and sealing the open end of a cell housing. The end cap assembly comprises a sealing disk underlying an end cap, and a metal support disk between the end cap and the sealing disk. The metal support disk has a plurality of primary vent apertures and a plurality of secondary vent apertures through its surface. The primary vent apertures are spaced apart along a path located at a greater distance from the central longitudinal axis of the metal support disk than the secondary vent apertures. The insulating sealing disk may have a thinned portion therein forming an rupturable membrane circumventing the central hub of the sealing disk. The insulating sealing disk may have protrusions emanating from its top surface to deflect the membrane during rupture. The venting system releases internal gases rapidly from the cell in the event of an abusive or short circuit discharge.

Abstract: A non-hermetically sealed, electrochemical power source, includes a first electrode, a second electrode, a separator between the first electrode and the second electrode, and a membrane in fluid communication with an environment external to the battery. The second electrode is between the separator and the membrane. The membrane includes a first portion having a different property, e.g., density, porosity, mass transport resistance, thickness, or gas permeability, than a second portion of the membrane. Methods of designing an electrochemical cell cartridge are also disclosed.

Abstract: And end cap assembly and venting system therein for closing and sealng the open end of a cell housing. The end cap assembly comprises a sealing disk underlying an end cap, and a metal support disk between the end cap and the sealing disk. The metal support disk has a plurality of primary vent apertures and a plurality of secondary vent apertures through its surface. The primary vent apertures are spaced apart along a path located at a greater distance from the central longitudinal axis of the metal support disk than the secondary vent apertures. The insulating sealing disk may have a thinned portion therein forming an rupturable membrane circumventing the central hub of the sealing disk. The insulating sealing disk may have protrusions emanating from its top surface to deflect the membrane during rupture. The venting system releases internal gases rapidly from the cell in the event of an abusive or short circuit discharge.

Abstract: A non-hermetically sealed, electrochemical power source, includes a first electrode, a second electrode, a separator between the first electrode and the second electrode, and a membrane in fluid communication with an environment external to the battery. The second electrode is between the separator and the membrane. The membrane includes a first portion having a different property, e.g., density, porosity, mass transport resistance, thickness, or gas permeability, than a second portion of the membrane. Methods of designing an electrochemical cell cartridge are also disclosed.

Abstract: An end cap seal assembly for an electrochemical cell such as an alkaline cell is disclosed. The end cap assembly comprises a convoluted end cap which may also function as a cell terminal and an underlying insulating sealing disk. The insulating sealing disk comprises a central boss and radially extending arm terminating in a downwardly sloped elbow and upwardly sloped peripheral edge. The end cap disk has at least one vent aperture therethrough which faces the ambient environment. The insulating disk has an annular groove in its top or bottom surface, which preferably circumvents the central boss. The base of the groove defines an a rupturable membrane portion of the insulating sealing disk. The rupturable membrane is designed to rupture, preferably when the cell internal gas pressure reaches a level between about 150 and 900 psig (1034×103 and 6206×103 pascal gage) advantageously, between about 150 and 700 psig (1034×103 and 4827×103 pascal gage).

Abstract: An end cap seal assembly for an electrochemical cell such as an alkaline cell is disclosed. The end cap assembly comprises a convoluted end cap which may also function as a cell terminal and an underlying insulating sealing disk. The insulating sealing disk comprises a central boss and radially extending arm terminating in a downwardly sloped elbow and upwardly sloped peripheral edge. The end cap disk has at least one vent aperture therethrough which faces the ambient environment. The insulating disk has an annular groove in its top or bottom surface, which preferably circumvents the central boss. The base of the groove defines an a rupturable membrane portion of the insulating sealing disk. The rupturable membrane is designed to rupture, preferably when the cell internal gas pressure reaches a level between about 150 and 900 psig (1034×103 and 6206×103 pascal gage) advantageously, between about 150 and 700 psig (1034×103 and 4827×103 pascal gage).

Abstract: A non-hermetically sealed, electrochemical power source, includes a first electrode, a second electrode, a separator between the first electrode and the second electrode, and a membrane in fluid communication with an environment external to the battery. The second electrode is between the separator and the membrane. The membrane includes a first portion having a different property, e.g., density, porosity, mass transport resistance, thickness, or gas permeability, than a second portion of the membrane. Methods of designing an electrochemical cell cartridge are also disclosed.