Elastomeric gasket contacting the inner surface of the casing lid of a pulse dischargeable lithium electrochemical cell

1 . An electrochemical cell, comprising:

a) a casing comprising:

i) a container having a sidewall extending from a closed bottom wall to an open end; and

ii) a lid closing the open end of the container, wherein the lid has inner and outer lid surfaces extending to a peripheral edge, and wherein the lid has a terminal pin opening and an electrolyte fill port; and

b) a terminal pin extending through the terminal pin opening;

c) a glass-to-metal seal (GTMS) comprises a sealing glass that electrically isolates the terminal pin from the lid so that the terminal pin is in a non-conductive relation with the casing;

d) an elastomeric gasket comprising a distal gasket surface spaced from a proximal gasket surface, wherein the distal gasket surface is sealed to the inner surface of the lid;

e) an electrode assembly housed inside the casing, the electrode assembly comprising:

i) an anode comprising an anode active material supported on an anode current collector, wherein the anode current collector comprises at least one anode lead conductively connected to the casing;

ii) a cathode comprising a cathode active material supported on a cathode current collector, wherein the cathode current collector comprises at least one cathode tab extending outwardly beyond a perimeter edge of the cathode current collector, the perimeter edge from which the at least one cathode tab extends being spaced closer to the lid than a remainder of the cathode current collector; and

iii) at least one separator positioned between the anode and the cathode to prevent direct physical contact between them; and

f) an insulator compartment, comprising:

i) a first insulator member having a first surrounding sidewall extending from a first insulator face wall to a first sidewall outer edge, wherein the first insulator face wall contacts the proximal gasket surface of the elastomeric gasket sealed to the inner surface of the lid with the first surrounding sidewall extending away from the lid toward the upper edge of the electrode assembly, and wherein the terminal pin extends through the elastomeric gasket and through a first opening in the first insulator face wall; and

ii) a second insulator member having a second surrounding sidewall extending from a second insulator face wall to a second sidewall outer edge, the second insulator face wall being disposed adjacent to the perimeter edge of the cathode current collector with the second surrounding sidewall extending away from the perimeter edge of the cathode current collector toward the lid, wherein the cathode tab extends through a second opening in the second insulator face wall,

iii) wherein the first and second insulator members are mated to each other with one of the first and second outer edges of the first and second surrounding sidewalls facing the other of the first and second insulator face walls so that at least a portion of the first surrounding sidewall is in an overlapping, direct contact relationship with at least a portion of the second surrounding sidewall to thereby form the insulator compartment residing between the perimeter edge of the cathode current collector and the elastomeric gasket sealed to the inner surface of the lid, and

iv) wherein the terminal pin is connected to the cathode tab in the insulator compartment; and

g) an electrolyte provided in the casing to activate the electrode assembly.

2 . The electrochemical cell of claim 1 , wherein the elastomeric gasket comprises an O-ring gasket portion that contacts the sealing glass of the GTMS and a sheet-shaped gasket portion that is connected to the O-ring gasket portion and sealed to the inner surface of the lid.

3 . The electrochemical cell of claim 2 , wherein the O-ring gasket portion and the sheet-shaped gasket portion of the elastomeric gasket are connected together as a unitary elastomeric gasket.

4 . The electrochemical cell of claim 2 , wherein the sealing glass of the GTMS has an inner meniscus that is recessed distally from the inner surface of the lid with the O-ring gasket portion of the elastomeric gasket contacting the inner meniscus.

5 . The electrochemical cell of claim 2 , wherein the peripheral edge of the lid comprises spaced apart upper and lower side edge portions that meet with right and left end edge portions, and wherein the sheet-shaped gasket portion of the elastomeric gasket extends to the lid upper and lower side edge portions but is spaced from the right and left end edge portions of the lid to provide uncovered portions of the inner lid surface that extend from an outer edge of the elastomeric gasket to an inner surface of the container sidewall, and wherein the uncovered portions of the inner lid surface are where lithium clusters can contact the lid without bridging to the at least one cathode current tab connected to the terminal pin.

6 . The electrochemical cell of claim 1 , wherein the lid does not have a ferrule so that the sealing glass of the GTMS seals directly to the terminal pin and directly to the lid in the terminal pin opening.

7 . The electrochemical cell of claim 1 , wherein the electrode assembly further comprises at least two cathode plates, each cathode plate having a cathode tab conductively connected to the terminal pin inside the insulator compartment, and wherein at least a portion of the anode resides between the at least two cathode plates.

8 . The electrochemical cell of claim 7 , wherein the anode has a serpentine shape with one of the at least two cathode plates interleaved between a fold of the serpentine anode, and wherein each of the at least two cathode plates has a cathode tab housed inside the insulator compartment where the cathode tabs are conductively connected to a cathode bridge, and wherein the cathode bridge is conductively connected to the terminal pin in the insulator compartment.

9 . The electrochemical cell of claim 7 , wherein the second opening in the second insulator face wall of the second insulator member is configured to receive the cathode tabs comprising the at least two cathodes connected to the cathode bridge.

10 . The electrochemical cell of claim 1 , wherein the first and second insulator members of the insulator compartment are composed of a material that is impervious to lithium-ion flow therethrough and which is selected from polyethylene, polyethylenechlorotrifluoroethylene, polypropylene, ETFE, and PTFE, and combinations thereof.

11 . The electrochemical cell of claim 1 , wherein the cathode active material is selected from silver vanadium oxide, CF x , SVO/current collector/CF x , copper silver vanadium oxide, V 2 O 5 , MnO 2 , LiCoO 2 , LiNiO 2 , LiMn 2 O 4 , TiS 2 , Cu 2 S, FeS, FeS 2 , Ag 2 O, Ag 2 O 2 , CuF 2 , Ag 2 CrO 4 , copper oxide, and copper vanadium oxide, and mixtures thereof.

12 . An electrochemical cell, comprising:

a) a casing comprising:

i) a container having a sidewall extending from a closed bottom wall to an open end; and

ii) a lid closing the open end of the container, wherein the lid has inner and outer lid surfaces extending to a peripheral edge, and wherein the lid has a terminal pin opening and an electrolyte fill port, and wherein the lid does not have a ferrule; and

b) a terminal pin extending through the terminal pin opening in the lid with a sealing glass directly contacting the terminal pin and the lid at the terminal pin opening so that the terminal pin is in a non-conductive relation with the casing;

c) an elastomeric gasket comprising an O-ring gasket portion that contacts the sealing glass and a sheet-shaped gasket portion that is connected to the O-ring gasket portion and sealed to the inner surface of the lid;

d) an electrode assembly housed inside the casing, the electrode assembly comprising:

i) an anode comprising lithium supported on an anode current collector, wherein the anode current collector comprises at least one anode lead conductively connected to the casing;

ii) a cathode comprising a cathode current collector comprising opposed major surfaces, wherein silver vanadium oxide and CF x are contacted to the opposed major surfaces of the cathode current collector, and wherein the cathode current collector comprises a cathode tab extending outwardly beyond a perimeter edge of the cathode current collector; and

iii) at least one separator positioned between the anode and the cathode to prevent direct physical contact between them; and

e) an insulator compartment, comprising:

i) a first insulator member having a first surrounding sidewall extending from a first insulator face wall to a first sidewall outer edge, wherein the first insulator face wall contacts the elastomeric gasket sealed to the inner surface of the lid with the first surrounding sidewall extending away from the lid toward the upper edge of the electrode assembly, and wherein the terminal pin extends through the O-ring gasket portion of the elastomeric gasket and through a first opening in the first insulator face wall; and

ii) a second insulator member having a second surrounding sidewall extending from a second insulator face wall to a second sidewall outer edge, the second insulator face wall being disposed adjacent to the perimeter edge of the cathode current collector with the second surrounding sidewall extending away from the perimeter edge of the cathode current collector toward the lid, wherein the cathode tab extends through a second opening in the second insulator face wall,

iii) wherein the first and second insulator members are mated to each other with one of the first and second outer edges of the first and second surrounding sidewalls facing the other of the first and second insulator face walls so that at least a portion of the first surrounding sidewall is in an overlapping, direct contact relationship with at least a portion of the second surrounding sidewall to thereby form the insulator compartment residing between the perimeter edge of the cathode current collector and the elastomeric gasket sealed to the inner surface of the lid, and

iv) wherein the terminal pin is connected to the cathode tab in the insulator compartment; and

f) an electrolyte provided in the casing to activate the electrode assembly.

13 . The electrochemical cell of claim 12 , wherein the O-ring gasket portion and the sheet-shaped gasket portion of the elastomeric gasket are connected together as a unitary elastomeric gasket.

14 . The electrochemical cell of claim 12 , wherein the sealing glass has an inner meniscus that is recessed distally from the inner surface of the lid with the O-ring gasket portion of the elastomeric gasket contacting the inner meniscus.

15 . The electrochemical cell of claim 12 , wherein the peripheral edge of the lid comprises spaced apart upper and lower side edge portions that meet with right and left end edge portions, and wherein the sheet-shaped gasket portion of the elastomeric gasket extends to the upper and lower side edge portions but is spaced from the right and left end edge portions of the lid to provide uncovered portions of the inner lid surface that extend from an outer edge of the elastomeric gasket to an inner surface of the container sidewall, and wherein the uncovered portions of the inner lid surface are where lithium clusters can contact the lid without bridging to the at least one cathode current tab connected to the terminal pin.

16 . The electrochemical cell of claim 12 , wherein the elastomeric gasket has a distal gasket surface spaced from a proximal gasket surface, and wherein the distal gasket surface is sealed to the inner surface of the lid, and the first insulator face wall of the first insulator member of the insulator compartment directly contacts the proximal gasket surface.

17 . The electrochemical cell of claim 12 , wherein the electrode assembly further comprises at least two cathode plates, each cathode plate having a cathode tab conductively connected to the terminal pin inside the insulator compartment, and wherein at least a portion of the anode resides between the at least two cathode plates.

18 . The electrochemical cell of claim 17 , wherein the anode has a serpentine shape with one of the at least two cathode plates interleaved between a fold of the serpentine anode, and wherein each of the at least two cathode plates has a cathode tab housed inside the insulator compartment where the cathode tabs are conductively connected to a cathode bridge, and wherein the cathode bridge is conductively connected to the terminal pin in the insulator compartment.