ELECTRODE FOR AN ELECTROCHEMICAL CELL AND PROCESS FOR MAKING THE ELECTRODE
(19)AUSTRALIAN PATENT OFFICE(54) Title ELECTRODE FOR AN ELECTROCHEMICAL CELL AND PROCESS FOR MAKING THE ELECTRODE (21) Application No: 2003249263 (22) Application Date: 2003.07.14 (87) WIPONo: WOCM/010513 (30) Priority Data (31) Number (32) Date (33) Country 10/1997022002.07.19 US (43) Publication Date : 2004.02.09 (43) Publication Journal Date : 2004.03.18 (71) Applicant(s) EVEREADY BATTERY COMPANY, INC. (72) Inventor(s) HORN, Quinn, C. (H) Application NoAU2003249263 A1(19)AUSTRALIAN PATENT OFFICE(54) Title ELECTRODE FOR AN ELECTROCHEMICAL CELL AND PROCESS FOR MAKING THE ELECTRODE (21) Application No: 2003249263 (22) Application Date: 2003.07.14 (87) WIPONo: WOCM/010513 (30) Priority Data (31) Number (32) Date (33) Country 10/1997022002.07.19 US (43) Publication Date : 2004.02.09 (43) Publication Journal Date : 2004.03.18 (71) Applicant(s) EVEREADY BATTERY COMPANY, INC. (72) Inventor(s) HORN, Quinn, C. A cell and a method for preparing an electrochemical cell having an electrode containing a mixture of agglomerated particles and nonagglomerated particles are disclosed. The process enables the incorporation of small particles of electrochemically active material, such as zinc dust, into the electrode's formula while preventing undesirable segmentation of the particles. CLAIMS I claim: 1. A process for manufacturing an electrochemical cell, comprising the steps of (a) providing an open ended container having a first electrode defining a cavity lined by a separator; (b) providing a second electrode comprising a mixture of nonagglomerated particles of electrochemically active material and agglomerates of electrochemically active material; (c) disposing said mixture into said separator lined cavity; and (d) securing a closure member to the open end of said container.
2. The process of claim 1 wherein said agglomerates comprise agglomerated particles.
3. The process of claim 2 wherein said agglomerated particles comprise less than fifty weight percent of said electrochemically active material.
4. The process of claim 2 wherein said agglomerated particles comprise less than twenty-five weight percent of said electrochemically active material.
5. The process of claim 2 wherein said agglomerated particles comprise less than five weight percent of said electrochemically active material.
6. The process of claim 2 wherein said agglomerated particles comprise less than one weight percent of said electrochemically active material.
7. The process of claim 1 wherein said electrochemically active material comprises zinc.
8. The process of claim 2 wherein said agglomerates comprise particles that pass through a 200 mesh opening in a sieving screen. <Desc/Clms Page number 11> The process of claim 2 wherein said agglomerates consist essentially of particles that pass through a 200 mesh opening in a sieving screen.
The process of claim 2 wherein said agglomerates consist of particles that pass through a 200 mesh opening in a sieving screen.
The process of claim 2 wherein said agglomerates comprise particles that pass through a 325 mesh opening in a sieving screen.
The process of claim 2 wherein said agglomerates consist essentially of particles that pass through a 325 mesh opening in a sieving screen.
The process of claim 2 wherein said agglomerates consist of particles that pass through a 325 mesh opening in a sieving screen.
The process of claim 2 wherein said nonagglomerated particles cannot pass through a 200 mesh opening in a sieving screen.
The process of claim 2 wherein said nonagglomerated particles cannot pass through a 325 mesh opening in a sieving screen.
The process. of claim 1 wherein said agglomerates comprise an agglomerant.
The process of claim 16 wherein said agglomerant comprises an organic material.
The process of claim 16 wherein said agglomerant comprises an inorganic material.
The process of claim 18 wherein said agglomerant comprises a metal. <Desc/Clms Page number 12> 20. An electrochemical cell, comprising: (a) an open ended container defining a cavity; (b) a first electrode disposed within said cavity; (c) a second electrode disposed within said cavity, said second electrode comprising a mixture of nonagglomerated particles of electrochemically active material and agglomerates of electrochemically active material; (d) a separator forming an ionically permeable and electrically nonconductive barrier between said first electrode and said second electrode; and (e) a closure member secured to the open end of said container.
21. The electrochemical cell of claim 20, wherein said agglomerates comprise agglomerated particles.
22. The electrochemical cell of claim 20, wherein said agglomerates comprise an agglomerant.
23. The electrochemical cell of claim 21 wherein said agglomerated particles comprise less than fifty weight percent of said electrochemically active material.
24. The electrochemical cell of claim 21 wherein said agglomerated particles comprise less than twenty-five weight percent of said electrochemically active material.
25. The electrochemical cell of claim 21 wherein said agglomerated particles comprise less than fifteen weight percent of said electrochemically active material.
26. The electrochemical cell of claim 21 wherein said agglomerated particles comprise less than five weight percent of said electrochemically active material. <Desc/Clms Page number 13> The electrochemical cell of claim 21 wherein said agglomerated particles comprise less than two weight percent of said electrochemically active material.
The electrochemical cell of claim 20 wherein said nonagglomerated particles comprise at least fifty weight percent of said electrochemically active material.
The electrochemical cell of claim 20 wherein said nonagglomerated particles comprise at least seventy-five weight percent of said electrochemically active material.
The electrochemical cell of claim 20 wherein said nonagglomerated particles comprise at least ninety weight percent of said electrochemically active material.
The electrochemical cell of claim 20 wherein said nonagglomerated particles comprise at least ninety-five weight percent of said electrochemically active material.
The electrochemical cell of claim 20, wherein said electrochemically active material comprises zinc.
The electrochemical cell of claim 20 wherein said agglomerates comprise particles that pass through a 200 mesh opening in a sieving screen.
The electrochemical cell of claim 20 wherein said agglomerates consist essentially of particles that pass through a 200 mesh opening in a sieving screen. <Desc/Clms Page number 14> 35. The electrochemical cell of claim 20 wherein said agglomerate consists of particles that pass through a 200 mesh opening in a sieving screen.
36. The electrochemical cell of claim 20 wherein said agglomerates comprise particles that pass through a 325 mesh opening in a sieving screen.
37. The electrochemical cell of claim 20 wherein said agglomerates consist essentially of particles that pass through a 325 mesh opening in a sieving screen.
38. The electrochemical cell of claim 20 wherein said agglomerates consist of particles that pass through a 325 mesh opening in a sieving screen.
39. The electrochemical cell of claim 20 wherein said nonagglomerated particles cannot pass through a 200 mesh opening in a sieving screen.
40. The electrochemical cell of claim 20 wherein said nonagglomerated particles cannot pass through a 325 mesh opening in a sieving screen.
41. The electrochemical cell of claim 20, wherein said electrochemically active material comprises zinc alloy.
42. The electrochemical cell of claim 20 wherein said second electrode comprises a gel.