Electrochemical cell having a multiplate electrode assembly housed in an irregularly shaped casing

An electrochemical cell, which comprises:

• a) an anode comprising an anode current collector with an anode material contacted thereto to provide at least two anode plates;
• b) a cathode comprising a cathode current collector with a cathode active material contacted thereto to provide at least one cathode plate;
• c) a casing comprising spaced apart first and second major casing side walls extending to and meeting with an end wall, the casing end wall and first and second major casing side walls extending to an opening, wherein the casing end wall comprises a right end wall portion and a left end wall portion, both extending from the opening to a bottom wall portion with one of the right and left end wall portions being longer than the other such that the bottom wall curves upwardly from the longer one of the right and left end wall portions to the other end, wherein the first and second major casing side walls are of substantially the same shape, but of dissimilar area sizes such that at least the right and left end walls angle toward each other, and wherein the at least two anode plates are of substantially the same shape and area as the respective first and second casing major side walls with the at least one cathode plate being intermediate them and of substantially the same shape as both anode plates;
• d) a separator disposed intermediate the anode plates and the at least one cathode plate;
• e) a lid closing the opening of the casing;
• f) first and second terminals connected to the respective anode and cathode;
• and
• g) an electrolyte in the casing to activate the anode and cathode.

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

• a) providing an anode comprising an anode current collector comprising a right end wall and a left end wall, both extending from an upper wall to a bottom wall and being intermediate first and second major sides and then contacting an anode material to at least one of the major sides of the anode current collector to provide at least one anode plate;
• b) providing a cathode comprising a cathode current collector comprising a right end wall and a left end wall, both extending from an upper wall to a bottom wall and being intermediate first and second major sides and then contacting a cathode active material to at least one of the major sides of the cathode current collector to provide at least one cathode plate;
• c) providing a casing comprising spaced apart first and second major casing side walls extending to and meeting with an end wall, with the casing end wall and first and second major casing side walls extending to an opening, wherein the casing end wall comprises a right end wall portion and a left end wall portion, both extending from the opening to a bottom wall portion with one of the right and left end wall portions being longer than the other such that the bottom wall curves upwardly from the longer one of the right and left end wall portions to the other end wall portion and wherein the at least one major anode plate and the at least one major cathode plate are of substantially the same area as the respective first and second casing major side walls with their respective current collectors each having their bottom walls curving upwardly from the aligned longer ones of the right and left end walls to the other end walls, wherein the coinciding longer ones of the right and left end walls of the respective anode and cathode current collectors are aligned with the longer one of the right and left end wall portions of the casing;
• d) providing a cell stack comprising a separator disposed intermediate the anode material of the at least one anode plate facing the cathode active material of the at least one cathode plate;
• e) housing the cell stack inside the casing;
• f) closing the opening of the casing with a lid secured thereto;
• g) connecting respective terminals to each of the anode and the cathode;
• and
• h) filling an electrolyte into the casing to activate the anode and the cathode.