Electrochemical cell having a serpentine anode with a plurality of interleaved cathode plates having extending tabs stacked and connected to each other by a welded surrounding metal hoop

An electrochemical cell, comprising:

• a) a casing;
• b) an electrode assembly housed inside the casing, the electrode assembly comprising:
• i) at least a first cathode and a second cathode, the first cathode having a first configuration of:
• SVO (silver vanadium oxide)/first current collector/CFx (carbon monofluoride)/second current collector/SVO, and the second cathode having a second configuration of:
• SVO/third current collector/CFx/fourth current collector/SVO, wherein:
• A) the first cathode current collector has a first cathode tab with opposed first and second major sides;
• and
• B) the second cathode current collector has a second cathode tab with opposed third and fourth major sides;
• C) the third cathode current collector has a third cathode tab with opposed fifth and sixth major sides;
• and
• D) the fourth cathode current collector has a fourth cathode tab with opposed seventh and eighth major sides;
• E) a cathode lead extending from a cathode lead proximal portion to a cathode lead distal portion, wherein, with the first and second cathodes in a side-by-side arrangement, a first section and a second section of the cathode lead proximal portion contact the respective eighth major side of the fourth cathode tab and the first major side of the first cathode tab with a third section of the cathode lead proximal portion contacting the first section of the cathode lead proximal portion;
• and
• F) at least one weld contacting the first, second and third sections of the cathode lead proximal portion and the first, second, third and fourth cathode tabs;
• ii) at least one anode positioned between the side-by-side first and second cathodes, the anode comprising an anode current collector having at least one anode tab connected to an anode plate, wherein an anode active material is contacted to the anode plate, and wherein the at least one anode tab is connected to the casing serving as a negative terminal for the cell;
• and
• iii) a separator residing between the anode and the first and second cathodes;
• and
• c) a feedthrough comprising a terminal pin of a glass-to-metal seal supported by the casing, wherein the terminal pin extends from a terminal pin proximal end electrically connected to the cathode lead distal portion to a terminal pin distal end located outside the casing to thereby serve as a positive terminal for the cell;
• and
• d) an electrolyte in the casing activating the electrode assembly.

A method for providing an electrochemical cell, comprising the steps of:

• a) providing an open-ended container;
• b) providing an electrode assembly, comprising:
• i) at least a first cathode and a second cathode, wherein:
• A) the first cathode comprises a first cathode current collector having a first cathode tab connected to a first cathode plate, wherein a first cathode active material is contacted to the first cathode plate, and wherein the first cathode tab has opposed first and second major sides;
• and
• B) the second cathode comprises a second cathode current collector having a second cathode tab connected to a second cathode plate, wherein a second cathode active material is contacted to the second cathode plate, and wherein the second cathode tab has opposed third and fourth major sides;
• ii) providing a cathode lead extending from a cathode lead proximal portion to a cathode lead distal portion, wherein, with the first and second cathodes in a side-by-side arrangement, wrapping the cathode lead around the first and second cathode tabs so that a first section and a second section of the cathode lead proximal portion contact the respective fourth major side of the second cathode tab and the first major side of the first cathode tab with a third section of the cathode lead proximal portion contacting the first section of the cathode lead proximal portion;
• and
• iii) welding the first, second and third sections of the cathode lead proximal portion, and the first and second cathode tabs together;
• and
• iv) positioning at least one anode between the side-by-side first and second cathodes, the anode comprising an anode current collector having at least one tab connected to an anode plate, wherein an anode active material is contacted to the anode plate;
• and
• c) providing a lid sized and shaped to close the open end of the container;
• d) securing a feedthrough comprising a terminal pin of a glass-to-metal seal in an opening in the lid;
• e) electrically connecting a proximal end of the terminal pin to the cathode lead distal portion;
• f) housing the electrode assembly inside the container and then connecting the at least one anode tab to the container serving as a negative terminal for the cell;
• g) securing the lid to the container to close the open end thereof and thereby provide a casing with a distal end of the feedthrough terminal pin extending outside the casing, the terminal pin serving as a positive terminal for the cell;
• and
• h) filling an electrolyte into the casing through a fill port and then closing the fill port.