Header insulator for an electrochemical cell

An electrochemical cell, which comprises:

• a) a casing having a surrounding side wall extending to an open end of the casing;
• b) an electrode assembly comprising an electrically associated first electrode and a second electrode with an intermediate separator disposed inside the casing;
• c) a lid sealed to the open end of the casing, the lid comprising an electrolyte fill ferrule and a terminal ferrule;
• d) a header comprising a generally planar header body having an upper surface proximate a lower surface of the lid and a spaced apart lower surface providing the header body with a thickness between the upper and lower surfaces;
• e) a terminal lead supported in the terminal ferrule and comprising a first end connected to the first electrode and a second end connectable to a load, and wherein the second electrode is connected to a second terminal;
• f) an electrolyte solution provided in the casing to activate the electrode assembly;
• g) a seal for the electrolyte fill ferrule;
• and
• h) wherein the header comprises a first structure depending from the header body to cover at least a portion of the terminal ferrule, a second structure depending from the header body to prevent movement of the electrode assembly inside the casing, and a third structure depending from the header body to cover at least a portion of the fill ferrule.

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

• a) providing a casing having a surrounding side wall extending to an open end of the casing;
• b) housing an electrode assembly comprising an electrically associated first electrode and a second electrode with an intermediate separator disposed inside the casing;
• c) providing a header having a generally planar header body supported on the electrode assembly, the header having an upper surface and a spaced apart lower surface providing the header body with a thickness between the upper and lower surfaces;
• d) sealing a lid to the open end of the casing, the lid comprising an electrolyte fill ferrule and a terminal ferrule, wherein the upper surface of the header is proximate the lid;
• e) providing a terminal lead supported in the terminal ferrule, the terminal lead comprising a first end disposed inside the casing connected to the first electrode and a second end connectable to a load, and connecting the second electrode to a second terminal;
• f) filling an electrolyte solution into the casing through the fill ferrule;
• g) sealing the electrolyte fill ferrule;
• and
• h) wherein at least a portion of the terminal ferrule is covered by a first structure depending from the header body, and wherein the electrode assembly in prevented from moving inside the casing by a second structure depending from the header body, and wherein at least a portion of the fill ferrule is covered by a third structure depending from the header body.