Abstract: A method includes mixing a solvent with a dry cathode mixture to form a slurry. The dry cathode mixture includes a cathode active material, a conductive diluent, and a polymeric binder. The method further includes removing the solvent from the slurry to form a composition and calendering, in a first calendering step, the composition to form a sheet. The calendering the composition includes passing the composition between calender rollers.

Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.

Abstract: A resistance weld shielding control system includes a computer that is executed to control a fixture to receive and hold at least one part to be welded. The computer also controls one or more electrodes to apply electrical energy to the part for welding the at least one part, and controls a gas delivery system to direct an inert gas onto the part for shielding the part from the ambient atmosphere via a nozzle. The nozzle is configured in the fixture such that the fixture holds the nozzle in a fixed physical relationship to the part.

Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.

Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.

Abstract: A method includes mixing a solvent with a dry cathode mixture to form a slurry. The dry cathode mixture includes a cathode active material, a conductive diluent, and a polymeric binder. The method further includes removing the solvent from the slurry to form a composition and calendering, in a first calendering step, the composition to form a sheet. The calendering the composition includes passing the composition between calender rollers.

Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.

Abstract: In some embodiments, a battery, a cathode for a battery, and a method for making a cathode and a battery are provided. The method comprises the steps of at least combining an electrode active material, one or more conductive diluents, a binder and a solvent to form an electrode active mixture having a first solvent to powder weight ratio, reducing a solvent to powder weight ratio to form a paste, feeding the paste into a plastic tube; and calendering the plastic tube. A dry cathode mixture is provided. The dry cathode mixture includes a cathode active material, a conductive diluent and a polymeric binder. A solvent is mixed with the dry mixture to form a slurry. Solvent is removed from the slurry to form a doughy composition. The doughy composition is calender sheeted to form a sheet. The sheet is baked at a temperature of 30° C. to 120° C. for 15 minutes to 6 hours to form a dry sheet. The dry sheet is cut into coupons. The coupons are pressed to form a pressed coupon.

Abstract: A resistance weld shielding control system includes a computer that is executed to control a fixture to receive and hold at least one part to be welded. The computer also controls one or more electrodes to apply electrical energy to the part for welding the at least one part, and controls a gas delivery system to direct an inert gas onto the part for shielding the part from the ambient atmosphere via a nozzle. The nozzle is configured in the fixture such that the fixture holds the nozzle in a fixed physical relationship to the part.

Abstract: A resistance weld shielding control system includes a computer that is executed to control a fixture to receive and hold at least one part to be welded. The computer also controls one or more electrodes to apply electrical energy to the part for welding the at least one part, and controls a gas delivery system to direct an inert gas onto the part for shielding the part from the ambient atmosphere via a nozzle. The nozzle is configured in the fixture such that the fixture holds the nozzle in a fixed physical relationship to the part.

Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.

Abstract: Disclosed herein is a battery with a pouch-type enclosure for use with an implantable electronic device. The battery may have greater than 20 megaohms of isolation between the anode and the external surface of the pouch-type battery enclosure and the cathode and the external surface of the pouch-type battery enclosure. The battery may have a pouch-type enclosure with a contoured shape, including a cathode, anode, and electrolyte disposed within the pouch-type enclosure. The cathode and/or anode may have variable thicknesses. The variable thickness anode and/or cathode may be contoured in shape to at least partially provide the contoured shape of the pouch-type enclosure.

Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.

Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.

Abstract: Disclosed herein is a battery with a pouch-type enclosure for use with an implantable electronic device. The battery may have greater than 20 megaohms of isolation between the anode and the external surface of the pouch-type battery enclosure and the cathode and the external surface of the pouch-type battery enclosure. The battery may have a pouch-type enclosure with a contoured shape, including a cathode, anode, and electrolyte disposed within the pouch-type enclosure. The cathode and/or anode may have variable thicknesses. The variable thickness anode and/or cathode may be contoured in shape to at least partially provide the contoured shape of the pouch-type enclosure.

Abstract: A resistance weld shielding control system includes a computer that is executed to control a fixture to receive and hold at least one part to be welded. The computer also controls one or more electrodes to apply electrical energy to the part for welding the at least one part, and controls a gas delivery system to direct an inert gas onto the part for shielding the part from the ambient atmosphere via a nozzle. The nozzle is configured in the fixture such that the fixture holds the nozzle in a fixed physical relationship to the part.

Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.

Abstract: In some embodiments, a battery, a cathode for a battery, and a method for making a cathode and a battery are provided. The method comprises the steps of at least combining an electrode active material, one or more conductive diluents, a binder and a solvent to form an electrode active mixture having a first solvent to powder weight ratio, reducing a solvent to powder weight ratio to form a paste, feeding the paste into a plastic tube; and calendering the plastic tube. A dry cathode mixture is provided. The dry cathode mixture includes a cathode active material, a conductive diluent and a polymeric binder. A solvent is mixed with the dry mixture to form a slurry. Solvent is removed from the slurry to form a doughy composition. The doughy composition is calender sheeted to form a sheet. The sheet is baked at a temperature of 30° C. to 120° C. for 15 minutes to 6 hours to form a dry sheet. The dry sheet is cut into coupons. The coupons are pressed to form a pressed coupon.

Abstract: A battery includes an anode, an electrolyte, and a cathode. The cathode includes a current collector formed from a mesh structure with an opening pattern. The opening pattern does not include any angles less than 90 degrees, and the current collector has a first surface and a second surface opposite the first surface. The cathode also includes a first material layer bonded to the first surface of the current collector, and a second material layer bonded to the second surface of the current collector and to the first material layer through the current collector.

Abstract: A cathode element is formed as a continuous single element with a plurality of cathode leaves connected by cathode bridges. An anode element is similarly formed as a continuous single element with a plurality of anode leaves connected by anode bridges. The cathode element and anode element can be aligned and interleaved at spaces between adjacent leaves. The resulting battery pre-stack can then be folded along its bridges in alternating directions to form a battery stack whose layers alternate between an anode and cathode, and which requires minimal components and minimal or no welds.