Coin cell batteries including titanium-based contact materials with improved cold formability for safer coin cell batteries

An electrochemical coin cell comprising:

• a cylindrical casing comprising a negative contact surface and a side wall formed circumferentially about the negative contact surface, wherein the cylindrical casing defines an inner volume;
• an anode material disposed within a first portion of the inner volume;
• a cathode material disposed within a second portion of the inner volume;
• a separator disposed within the inner volume between the anode material and the cathode material;
• an electrolyte material disposed within the inner volume and configured to communicate ions between the anode material and the cathode material;
• and
• a planar positive contact surface comprising a titanium-containing material, the planar positive contact surface being disposed within or adjacent to the inner volume such that the anode material, the cathode material, the separator, and the electrolyte material are enclosed within the inner volume, wherein a portion of the side wall is joined to an edge of the planar negative contact surface to seal the inner volume of the cylindrical casing,
• wherein a thickness of the planar positive contact surface is between about 0.1 mm and about 0.5 mm, and
• wherein a bend radius at the edge of the planar positive contact surface relative to the side wall of the cylindrical casing is equal to or less than about 200% of the thickness of the planar positive contact surface.

A method for manufacturing a casing for an electrochemical coin cell, the method comprising:

• forming a first contact surface for the electrochemical coin cell from a first sheet consisting of a first material or cladded in the first material, the first material consisting of greater than about 99 wt. % titanium;
• forming a cylindrical housing cup from a second sheet consisting of a second material, the cylindrical housing cup comprising a substantially flat bottom and a side wall formed circumferentially about the substantially flat bottom, the substantially flat bottom forming a second contact surface for the electrochemical coin cell, the substantially flat bottom and the side wall forming an inner volume;
• disposing active electrochemical components into the inner volume of the cylindrical housing cup, the active electrochemical components comprising an anode, a separator, and a cathode, wherein the active electrochemical components are configured to produce an output open circuit voltage of at least 2.8 volts in the presence of a non-aqueous electrolyte;
• and
• sealing the active electrochemical components within the inner volume of the electrochemical coin cell by joining a circumferential edge of the first contact surface to one or more portions of the side wall of the cylindrical housing cup such that the first and second contact surfaces are in electrical communication with the active electrochemical components, wherein the circumferential edge of the first contact surface is joined to the one or more portions of the side wall of the cylindrical housing cup by bending or crimping one or more of the circumferential edge of the first contact surface or the one or more portions of the side wall of the cylindrical housing cup.