Feedthrough pin insulator, assembly and method for electrochemical cell

An electrochemical cell comprising:

• (a) means for housing having an open end;
• (b) means for forming an anode having an anodic means for current collecting disposed operatively in respect thereof;
• (c) means for forming a cathode having a cathodic means for current collecting disposed operatively in respect thereof, the cathode forming means being disposed operatively in respect of the anode forming means, the anode and cathode forming means being disposed within the housing means;
• (d) a means for forming a header assembly sealing the open end, comprising:
• (1) means for electrically connecting an external electrical circuit to the anode forming means, the electrical connection means having upper and lower ends, the lower end being connected electrically to the anodic current collecting means;
• (2) means for covering the open end of the housing means, the covering means having external and internal surfaces, the upper end of the electrical connection means extending through an aperture disposed in the covering means, the lower end of the electrical connection means being disposed beneath the internal surface and inside the housing means;
• (3) means for mounting the electrical connection means in the aperture, the mounting means being disposed within the aperture and in electrical contact with the covering means;
• (4) means for sealing disposed between the mounting means and the electrical connection means and in sealing engagement therewith;
• (5) means for insulating the electrical connection means from cell components at cathode electrical potential, the insulating means extending between the anode forming means and the mounting means, the insulating means comprising first and second portions, the first portion being disposed at a location near the internal surface, the first and second portions being disposed beneath the internal surface and inside the housing, at least portions of the feedthrough pin engaging or being enclosed within the feedthrough pin insulator, the feedthrough pin insulator having a gate attached to or forming part of the second portion, the gate being configured to prevent or inhibit anode material from being extruded or pushed therearound when the gate is disposed against a sidewall of an anode formation cavity during an anode formation process.

A method of forming an anode having a feedthrough pin insulator assembly attached thereto, the anode and feedthrough pin insulator assembly being suitable for use in an electrochemical cell comprising a metal housing having an open end, the anode having an anode current collector disposed operatively in respect thereof, a cathode having a cathode current collector disposed operatively in respect thereof, the cathode being disposed operatively in respect of the anode, the anode and cathode being disposed within the housing, a header assembly for sealing the open end comprising a feedthrough pin having upper and lower ends, the lower end being connected electrically to the anode current collector, a housing cover having external and internal surfaces, the upper end of the feedthrough pin extending through an aperture disposed in the cover, the lower end of the pin being disposed inside the housing and electrically connected to the anode, a ferrule disposed within the aperture and in electrical contact with the housing cover, an electrically insulative seal disposed between the ferrule and the pin and in sealing engagement therewith, a feedthrough pin insulator having first and second portions, the first portion being disposed at a location at or near the ferrule, the second portion being disposed at a location at or near the anode, the feedthrough pin insulator extending between the anode and the ferrule, at least portions of the feedthrough pin engaging or being enclosed within the feedthrough pin insulator, the feedthrough pin insulator electrically insulating the feedthrough pin from the ferrule and other cell components having the same electrical potential as the cathode, the feedthrough pin insulator having a gate attached to or forming part of the second portion, the gate having a sealing surface for preventing or inhibiting anode material from being extended or pushed therearound when the sealing surface is pushed against a sidewall of an anode formation cavity, the anode formation cavity having a preselected shape and configuration, during an anode compression step in the anode forming method, the method comprising the steps of:

• (a) providing a lower punch and corresponding lower block, the lower block having the anode formation cavity and a support block cavity formed therein, the anode formation cavity having a sidewall;
• (b) disposing the header assembly in the lower block such that that cover, the seal, the female, the upper end of the feedthrough pin and the first portion of the feedthrough pin insulator are disposed within the support block cavity and such that the sealing surface is disposed within the anode formation cavity and propinquant to the sidewall.
• (c) placing an anode pre-form in the anode formation cavity
• (d) placing an upper punch guide having an upper punch cavity atop the lower block;
• (e) placing an upper punch in the upper punch cavity;
• (f) pressing the upper punch against the anode pre-cut to cause the pre-cut to be compressed and extruded such that the anode pre-cut assumes substantially the shape and configuration of the anode formation cavity and such that the sealing surface is forced against the sidewall by the compressed and extruded anode pre-cut.