# US 6,296,961 B1 · Composite carbon sheet, and electrochemical cells made therewith > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 6,296,961 B1 - Document ID: US6296961B1 - Status: Granted - Kind: B1 - Application number: 09/262,976 - Filed: 1999-03-05 - Granted: 2001-10-02 - Earliest claimed: 1998-03-06 - Assignees: Rayovac Corporation - Inventors: Gregory Scott Moy; Michael Andrew Ward; Robert Brian Dopp; Robert Brian Loch; John Edward Oltman; Joseph Lynn Passaniti - Web page: https://patentgrep.com/patent/US6296961B1 ## CPC - H01M 4/8803: {Supports for the deposition of the catalytic active composition (H01M4/90 takes precedence)} - H01M 4/742: {perforated material} - H01M 4/8605: {Porous electrodes} - H01M 12/06: with one metallic and one gaseous electrode - H01M 50/1537: {for hybrid cells} - H01M 50/186: characterised by the disposition of the sealing members - H01M 50/193: Organic material - H01M 4/04: Processes of manufacture in general - H01M 4/70: characterised by shape or form - H01M 50/107: having curved cross-section, e.g. round or elliptic (H01M50/103, H01M50/109, H01M50/11 take precedence) - H01M 50/543: Terminals - H01M 2004/8689: {Positive electrodes} - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract Cathode assembly precursor cathode assembly (26) and elongate air depolarized electrochemical cells (10) made therewith. Cathode assembly precursor comprises a closed-loop elongate cathode current collector (32), and perforations (56) from outer to inner surfaces, and catalystically active carbon extending into the perforations (56). The current collector (32) can be cylindrical and can be free from longitudinal jointing, or can have a longitudinal joint (54), preferably free from overlap of the side wall. The current collector (32) can comprise an imperforate edge region at the top (42) and/or bottom (44), left (48) and/or right (46) edge. The perforations (56) define an open traction of the wall, of about 45 to about 70 percent. Typical cathode assemblies (26) have air diffusion member (36) on the outer surface of the cathode assembly (26). Such air diffusion member (36) typically has thickness of about 0.0025 to 0.005 inch (about 0.06 to about 0.13 mm.), and comprises a reduced thickness endless wrap extending at least 1.5 times, preferably 2 times, or 3 times, about the current collector (32), discouraging transfer of moisture vapor into or out of a cell, discouraging leakage, and controlling air diffusion rate. The diffusion member (36) extends beyond the top edge (42) of the current collector, and is folded in and down about the top edge (42) and inner surface (60) of the cathode assembly (26). The cathode current collector (32) can be mounted on a mandrel (93), the carbon sheet (80) passing through a nip defined between (i) support structure (192) having greater arc radius than the mandrel (93) and (ii) the mandrel (93), and applying force at the nip to consolidate the carbon (80) onto the side wall (58), passing air diffusion material (36) through the nip, and applying force to consolidate the air diffusion material (36) onto the carbon (80). The invention contemplates fabricating an air cathode assembly (26) comprising mounting the current collector (32) on a mandrel (93), defining an arc having a radius smaller than the arc of the cathode current collector (32), mounting the combination mandrel (93) and cathode current collector (32) in a stack (90) of assembly rolls (90A, 90B, 90C, 90D), making a sheet stack of carbon sheets (80s, 80B, 80C, 80D), passing the sheet stack through a nip, and applying force to the stack, reducing thickness of the stack, and passing air diffusion material (36) through the nips and applying force to consolidate the diffusion material (36) onto the carbon (80). ## Claims ### Claim 1 A cathode assembly precursor for use in an elongate air depolarized electrochemical cell, said cathode assembly precursor comprising: (a) a closed-loop elongate cathode current collector having a side wall extending along a length thereof, and having a thickness, a top and a top edge, a bottom, a first outer surface and a first inner surface, and an array of perforations extending through the thickness of the side wall, from the outer surface of the side wall to the inner surface of the side wall; and (b) a carbon catalyst on at least one of the first inner and first outer surfaces of the side wall of said cathode current collector and extending into and through the perforations in said cathode current collector such that distal surface portions of the carbon catalyst are interlocked with said cathode current collector about perimeter edges of the respective perforations at the other of the at least first inner surface and first outer surface of said cathode current collector, the resulting cathode assembly precursor thus having a second outer surface and a second inner surface, one of the second outer surface and the second inner surface of said cathode assembly precursor being defined in first part by the distal surface portions of the carbon catalyst and in second part by the respective surface of the cathode current collector. ### Claim 2 (depends on 1) A cathode assembly precursor as in claim 1, said cathode current collector comprising a cylindrical cathode current collector free from longitudinal jointing along the length of said cathode current collector. ### Claim 3 (depends on 1) A cathode assembly precursor as in claim 1, said cathode current collector comprising a longitudinally-extending joint free from overlap of elements of said side wall at said joint. ### Claim 4 (depends on 1) A cathode assembly precursor as in claim 1, said cathode current collector comprising interdigitated elements of said side wall joined to each other and thereby forming a longitudinally-extending joint on said side wall. ### Claim 5 (depends on 1) A cathode assembly precursor as in claim 1, said cathode current collector comprising an imperforate edge region at at least one of said top and said bottom. ### Claim 6 (depends on 1) A cathode assembly precursor as in claim 1, said cathode current collector comprising imperforate edge regions at said top and said bottom, together extending along no more than 20 percent of the length of said cathode current collector. ### Claim 7 (depends on 1) A cathode assembly precursor as in claim 1, said cathode current collector comprising imperforate edge regions at said top and said bottom, together extending along about 5 percent to about 15 percent of the length of said cathode current collector. ### Claim 8 (depends on 1) A cathode assembly precursor as in claim 1, the array of perforations defining a perforated area of said side wall, the array of perforations further defining an open fraction of said side wall, of about 45 percent to about 70 percent of the perforated area. ### Claim 9 (depends on 1) A cathode assembly precursor as in claim 1, the array of perforations defining a perforated area of said side wall, the array of perforations further defining an open fraction of said side wall, of about 49 percent to about 65 percent of the perforated area. ### Claim 10 (depends on 1) A cathode assembly precursor as in claim 1, respective ones of the perforations having perimeters defining corners therein, edges of said cathode current collector at the respective corners being effective to assist in holding said carbon catalyst securely mounted to said cathode current collector. ### Claim 11 (depends on 1) A cathode assembly precursor as in claim 1 wherein said carbon catalyst comprises carbon, polymeric binder, and manganese(II) moieties. ### Claim 12 (depends on 1) A cathode assembly precursor as in claim 1 wherein said carbon catalyst comprises a layer of said carbon catalyst disposed on one of the first inner and first outer surfaces of said cathode current collector, and extending into the perforations. ### Claim 13 (depends on 1) A cathode assembly precursor as in claim 1 wherein said carbon catalyst comprises a layer of said carbon catalyst disposed on at least one of the first inner and first outer surfaces of said cathode current collector, and extending through the perforations to the other of the first inner and first outer surfaces of said cathode current collector, and extending laterally outwardly from respective ones of the perforations along the other of the first inner and first outer surfaces of said cathode current collector. ### Claim 14 (depends on 13) A cathode assembly precursor as in claim 13 wherein said carbon catalyst covers substantially equal portions of the first inner and first outer surfaces of said cathode current collector. ### Claim 15 (depends on 1) A tubular cathode assembly comprising a cathode assembly precursor as in claim 1 and an air diffusion member mounted on the second outer surface of said cathode assembly precursor. ### Claim 16 (depends on 15) A tubular cathode assembly as in claim 15, said air diffusion member having a thickness of about 0.0025 inch to about 0.005 inch. ### Claim 17 (depends on 15) A tubular cathode assembly as in claim 15, said air diffusion member comprising a continuous wrap of air diffusion sheet material extending at least 1.5 times about a circumference of the second outer surface of said cathode assembly precursor, such that said air diffusion member effectively discourages transfer of moisture vapor into or out of a cell into which said cathode assembly is incorporated, discourages leakage of liquid electrolyte, and controls rate of diffusion of air into the cell. ### Claim 18 (depends on 15) A tubular cathode assembly as in claim 15, said air diffusion member comprising a continuous wrap of air diffusion sheet material extending at least 2 times about a circumference of the second outer surface of said cathode assembly precursor, such that said air diffusion member effectively discourages transfer of moisture vapor into or out of a cell into which said cathode assembly is incorporated, discourages leakage of liquid electrolyte, and controls rate of diffusion of air into the cell. ### Claim 19 (depends on 15) A tubular cathode assembly as in claim 15, said air diffusion member comprising a continuous wrap of air diffusion sheet material extending at least 3 times about a circumference of the second outer surface of said cathode assembly precursor, such that said air diffusion member effectively discourages transfer of moisture vapor into or out of a cell into which said cathode assembly is incorporated, discourages leakage of liquid electrolyte, and controls rate of diffusion of air into the cell. ### Claim 20 (depends on 15) A tubular cathode assembly as in claim 15, said air diffusion member comprising a continuous wrap of air diffusion sheet material extending at least 2 times about a circumference of the second outer surface of said cathode assembly precursor, the air diffusion sheet material having variations in thickness along the length of said air diffusion sheet material, of at least 5 percent, the at least two wraps attenuating the affect of the variations in thickness. ### Claim 21 (depends on 20) A tubular cathode assembly as in claim 20, air diffusion characteristics of said air diffusion member in said cathode assembly being different from air diffusion characteristics of corresponding air diffusion sheet material at rest and not mounted on said cathode assembly precursor, as affected by compressing of the mounted air diffusion member. ### Claim 22 (depends on 15) A tubular cathode assembly as in claim 15, a side edge of said diffusion member extending beyond the top edge of said cathode current collector, and being folded inwardly about the top edge and downwardly against the second inner surface of said cathode assembly precursor. ### Claim 23 (depends on 15) A tubular cathode assembly as in claim 15, including liquidous seal rings on said air diffusion member adjacent the top and bottom of said cathode current collector. ### Claim 24 (depends on 1) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a tubular cathode assembly comprising a cathode assembly precursor as in claim 1. ### Claim 25 (depends on 3) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a tubular cathode assembly comprising a cathode assembly precursor as in claim 3. ### Claim 26 (depends on 5) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a tubular cathode assembly comprising a cathode assembly precursor as in claim 5. ### Claim 27 (depends on 7) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a tubular cathode assembly comprising a cathode assembly precursor as in claim 7. ### Claim 28 (depends on 8) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a tubular cathode assembly comprising a cathode assembly precursor as in claim 8. ### Claim 29 (depends on 10) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a tubular cathode assembly comprising a cathode assembly precursor as in claim 10. ### Claim 30 (depends on 13) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a tubular cathode assembly comprising a cathode assembly precursor as in claim 13. ### Claim 31 (depends on 14) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a tubular cathode assembly comprising a cathode assembly precursor as in claim 14. ### Claim 32 (depends on 15) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 15. ### Claim 33 (depends on 16) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 16. ### Claim 34 (depends on 18) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 18. ### Claim 35 (depends on 19) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 19. ### Claim 36 (depends on 20) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 20. ### Claim 37 (depends on 21) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 21. ### Claim 38 (depends on 22) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 22. ### Claim 39 A cathode assembly precursor for use in an elongate air depolarized electrochemical cell, said cathode assembly precursor comprising: (a) a closed-loop elongate cathode current collector having a side wall extending along a length thereof, and having a thickness, a top and a top edge, a bottom, a first outer surface and a first inner surface, and an array of perforations extending through the thickness of the side wall, from the outer surface of the side wall to the inner surface of the side wall; and (b) a carbon catalyst on the side wall of said cathode current collector and extending into the perforations in said cathode current collector, the resulting cathode assembly precursor having a second outer surface and a second inner surface, an air diffusion member being disposed on the second outer surface of said cathode assembly precursor, the air diffusion member comprising a continuous wrap of air diffusion sheet material extending at least 2 times about a circumference of the second outer surface of said cathode assembly precursor, the air diffusion sheet material having variations in thickness along the length of said air diffusion sheet material, of at least 5 percent, the at least two wraps attenuating the affect of the variations in thickness. ### Claim 40 (depends on 39) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 39. ### Claim 41 (depends on 39) A tubular cathode assembly as in claim 39, air diffusion characteristics of said air diffusion member in said cathode assembly being different from air diffusion characteristics of corresponding air diffusion sheet material at rest and not mounted on said cathode assembly precursor, as affected by compressing of the mounted air diffusion member. ### Claim 42 (depends on 41) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 41. ### Claim 43 A cathode assembly precursor for use in an elongate air depolarized electrochemical cell, said cathode assembly precursor comprising: (a) a closed-loop elongate cathode current collector having a side wall extending along a length thereof, and having a thickness, a top and a top edge, a bottom, a first outer surface and a first inner surface, and an array of perforations extending through the thickness of the side wall, from the outer surface of the side wall to the inner surface of the side wall; and (b) a carbon catalyst on the side wall of said cathode current collector and extending into the perforations in said cathode current collector, the resulting cathode assembly precursor having a second outer surface and a second inner surface, an air diffusion member being disposed on the second outer surface of said cathode assembly precursor, a side edge of said air diffusion member extending beyond the top edge of said cathode current collector, and being folded inwardly about the top edge and downwardly against the second inner surface of said cathode assembly precursor. ### Claim 44 (depends on 43) An air depolarized electrochemical cell comprising an anode, a cathode, a separator, and electrolyte, said cathode comprising a cathode assembly as in claim 43.