ELECTROCHEMICAL CELL WITH MODERATE-RATE DISCHARGING CAPABILITY AND METHOD OF PRODUCTION
A method of forming cathode comprises (a) combining carbon and an active cathode material to form a dry mix; (b) mixing a binding material with a solvent to produce a first solution; (c) mixing a surfactant material with the first solution to form a combined solution; (d) combining the dry mix and the combined solution to form a paste; and (e) laminating the paste onto an expanded mesh aluminum current collector to form an cathode. A method of forming an electrochemical cell further comprises (f) laminating an active anode material on a current collector to form an anode; (g) mounting the anode and the cathode on opposite sides of a separator to form an electrode assembly; (h) encasing the electrode assembly within a housing and (i) filling at least a portion of the housing interior with an electrolyte.
1 . A method of forming an electrode comprising the steps of:
(a) combining carbon and an active electrode material to form a dry mix;
(b) mixing a binding material with a solvent to produce a first solution;
(c) mixing a surfactant material with said first solution to produce a combined;
(d) combining said dry mix and said combined solution to form a paste;
(e) laminating said paste onto an expanded mesh aluminum current collector to form an electrode.
2 . The method of claim 1 wherein said steps are performed sequentially.
3 . The method of claim 1 wherein said active electrode compound is polycarbon monofluoride.
4 . The method of claim 3 wherein said binding material is PTFE.
5 . The method of claim 3 wherein the surfactant material is sodium lauryl sulfate.
6 . The method of claim 1 wherein said electrode is a cathode.
7 . A method of forming an electrochemical cell comprising the steps of:
(a) combining carbon and an active cathode material to form a dry mix;
(b) mixing a binding material with a solvent to produce a first solution;
(c) mixing a surfactant material with said first solution to produce a combined solution;
(d) combining said dry mix and said combined solution to form a paste;
(e) laminating said paste onto an expanded mesh aluminum current collector to form a cathode:
(f) laminating an active anode material on a current collector to form an anode;
(g) mounting said anode and said cathode on opposite sides of a separator to form an electrode assembly;
(h) encasing said electrode assembly within a housing such that said anode faces said housing interior surface, said anode interposed between said active cathode material and said housing;
(i) filling at least a portion of said housing interior with an electrolyte.
8 . The method of claim 7 wherein said steps are performed sequentially.
9 . The method of claim 7 where said active anode material is selected from the group consisting of lithium, sodium, calcium, potassium and alloys thereof.
10 . The method of claim 7 where said electrolyte comprises at least one of propylene carbonate, tetrahydrofuran and a mixture of dimethyoxyethane with lithium perchlorate.
11 . The method of claim 10 where said electrolyte comprises a mixture of propylene carbonate, tetrahydrofuran and said mixture of dimethyoxyethane with lithium perchlorate.
12 . The method claim of 7 wherein said electrode assembly is spiral wound prior to encasing said electrode assembly within said housing.
13 . An electrode comprising an expanded mesh aluminum current collector having laminated thereon a paste formed by combining (a) a dry mix comprising carbon and an active electrode material, (b) a first solution comprising a binding material and a first solvent, and (c) a surfactant material.
14 . The electrode of claim 13 wherein said active electrode material is polycarbon monofluoride.
15 . The electrode of claim 13 wherein said binding material is PTFE.
16 . The electrode of claim 13 wherein the surfactant material is sodium lauryl sulfate.
17 . The electrode of claim 13 wherein said electrode is a cathode.
18 . An electrode assembly comprising:
(a) a cathode comprising an expanded mesh aluminum current collector having laminated thereon a paste formed by combining (1) a dry mix comprising carbon and an active cathode material, (2) a first solution comprising a binding material and a first solvent, and (3) a surfactant material;
(b) an anode comprising an active anode material laminated on a current collector;
(c) a separator interposed between said anode and said cathode.
19 . The electrode assembly of claim 18 wherein said active cathode material is polycarbon monofluoride.
20 . The electrode assembly of claim 19 wherein said binding material is PTFE.
21 . The electrode assembly of claim 19 wherein the surfactant material is sodium lauryl sulfate.
22 . The electrode assembly of claim 19 where said active anode material is selected from the group consisting of lithium, sodium, calcium, potassium and alloys thereof.
23 . An electrochemical cell comprising:
(a) a housing having an interior surface;
(b) an electrode assembly comprising:
(1) a cathode comprising an expanded mesh aluminum current collector having laminated thereon a paste formed by combining (i) a dry mix comprising carbon and an active cathode material, (ii) a first solution comprising a binding material and a first solvent, and (iii) a surfactant material;
(2) an anode comprising an active anode material laminated on a current collector;
(3) a separator interposed between said anode and said cathode;
(c) an electrolyte;
wherein said electrode assembly is encased within said housing such that said anode faces said housing interior surface, said anode is interposed between said active cathode material and said housing; and at least a portion of said housing interior is filled with said electrolyte.
24 . The electrochemical cell of claim 23 wherein said active cathode material is polycarbon monofluoride.
25 . The electrochemical cell of claim 24 wherein said binding material is PTFE.
26 . The electrochemical cell of claim 24 wherein the surfactant material is sodium lauryl sulfate.
27 . The electrochemical cell of claim 24 where said active anode material is selected from the group consisting of lithium, sodium, calcium, potassium and alloys thereof.
28 . The electrochemical cell of claim 24 where said electrolyte comprises at least one of propylene carbonate, tetrahydrofuran and a mixture of dimethyoxyethane with lithium perchlorate.
29 . The electrochemical cell of claim 24 where said electrolyte comprises a mixture of propylene carbonate, tetrahydrofuran and said mixture of dimethyoxyethane with lithium perchlorate.
30 . The electrochemical cell of claim of 24 wherein said electrode assembly is spiral wound.
31 . The electrochemical cell of claim 24 further comprising a feed-through assembly operatively connected to said housing, said feed-through assembly comprising a conductive pin electrical contacting said cathode and an insulating glass cylinder surrounding said conductive pin.
32 . The electrochemical cell of claim 31 wherein said insulating glass cylinder is selected from the group consisting of aluminasilicate glasses and calcium-boro-aluminate glasses.
33 . The electrochenical cell of claim 32 wherein said conductive pin is formed from molybdenum.