Embedded electrode conformations for balanced energy, power, and cost in an alkaline cell
AssigneeRechargeable Battery Corporation
InventorsBrendan Coffey, Charles Edward Sesock, David Manko, Bhavesh Patel, John Gordon
Life of this patent
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Abstract
A battery cell, such as a cylindrical or prismatic alkaline cell, is disclosed having significantly improved capacity utilization at mid-range power levels of discharge by implementing a curvilinear-like inner electrode configuration that provides moderated surface area between the inner and outer electrodes as compared to high-power discharge applications utilizing a densely corrugated geometry for the inner electrode.
Claims17
An electrochemical battery cell comprising:
- a cell housing defining an interior space having an interior surface, a first terminal, and a second terminal;
- and,
- an electrode sub-assembly disposed within the interior space, the electrode sub-assembly comprising:
- an inner electrode comprising a substantially flat gelled material and current collector configured in a curvilinear-like geometry defining at least one spaced region;
- a non-flowable outer electrode assembly formed about the inner electrode such that an outer extent of the electrode sub-assembly substantially conforms to a contour defined by the interior space of the cell housing;
- and,
- a separator encapsulating the inner electrode;
- wherein the outer electrode assembly is in ionic communication with the inner electrode and in electrical communication with the first terminal of the cell housing, and the inner electrode is in electrical communication with the second terminal of the housing.
A method of manufacturing an electrochemical battery cell, the method comprising the steps of:
- providing a cell housing defining an interior space having an interior surface, a first terminal, and a second terminal;
- and,
- forming an electrode sub-assembly comprising:
- an inner electrode including a substantially flat gelled material and a current collector configured in a curvilinear-like geometry defining at least one spaced region;
- a non-flowable outer electrode assembly substantially formed about the inner electrode such that an outer extent of the electrode sub-assembly substantially conforms to a contour defined by the interior space of the cell housing;
- and,
- a separator encapsulating the inner electrode,
- wherein the electrode sub-assembly being disposed within the interior space of the cell housing.
An electrochemical battery cell comprising:
- a cell housing defining an interior space having an interior surface, a first terminal and a second terminal;
- and,
- an electrode assembly disposed within the interior space comprising:
- a first cathode formed into a ring having an inner surface and an outer surface, the outer surface adjacent the cell housing;
- a gelled anode material and a current collector, the gelled material and current collector encapsulated by a separator formed into an s-shape having two folds and adjacent to the inner surface of the first cathode;
- and,
- a second cathode and a third cathode each substantially surrounded in a fold of the gelled anode material;
- the first cathode, the second cathode and the third cathode in electrical communication with the first terminal and the gelled anode material in electrical communication with the second terminal.
Dependencies are inferred from the claim text.