Electrochemical cell

Abstract

An electrochemical cell that converts chemical energy to electrical energy includes a cathode with an active material of fluorinated carbon on a perforated metal cathode current collector, a lithium anode on a perforated metal anode current collector, a stepped header, a stable electrolyte, and a separator. In various embodiments, an anode current collector design, a cathode current collector design, a stepped header design, a cathode formulation, an electrolyte formulation, a separator, and a battery incorporating the electrochemical cell are provided.

1 . A cell comprising:
 a housing;   a cathode current collector, in the housing, including a cathode tab and a cathode plate, and the cathode tab including a tab area, and the cathode plate including a plate area and a peripheral edge that surrounds at least a portion of the plate area, and
 the peripheral edge including a plurality of partial perforations; and 
 the plate area including a plurality of interior perforations; 
   an anode current collector, in the housing, including an anode tab;   an anode, in the housing, provided adjacent the anode current collector; and   a cathode, in the housing, provided adjacent to the cathode current collector.   
     
     
         2 . The cell according to  claim 1 , wherein the cell is constructed of material so as to be configured to be an implantable in a human. 
     
     
         3 . The cell according to  claim 1 , wherein the cathode current collector is constructed of at least one selected from the group consisting of stainless steel, aluminum and titanium. 
     
     
         4 . The cell according to  claim 1 , wherein the plate area including a plurality of interior perforations, the plurality of interior perforations including large perforations and small perforations, and the small perforations being smaller than the large perforations. 
     
     
         5 . The cell according to  claim 4 , wherein the large perforations are in the form of circles and the small perforations are in the form of circles. 
     
     
         6 . The cell according to  claim 5 , wherein the large perforations are in a range of about 2.6 millimeters to about 2.3 millimeters in diameter and the small perforations are be in a range of about 1.8 millimeters to about 2.1 millimeters in diameter. 
     
     
         7 . The cell according to  claim 5 , wherein the large perforations are provided in a line along a center line of the cathode plate. 
     
     
         8 . The cell according to  claim 4 , wherein an area of the interior perforations constitutes a perforated area, and a ratio of the perforated area to the plate area is about 0.6. 
     
     
         9 . The cell according to  claim 4 , wherein the partial perforations are provided on opposing sides and on a bottom portion of the cathode plate. 
     
     
         10 . The cell according to  claim 9 , wherein at least some of the plurality of partial perforations is of a diameter that is about the same diameter as the large perforations in the plate area. 
     
     
         11 . The cell according to  claim 9 , wherein at least some of the partial perforations are arranged in pairs, with each partial perforation of the pair on opposing sides of the cathode plate. 
     
     
         12 . The cell according to  claim 11 , wherein the partial perforations, on opposing sides of the cathode plate and arranged in pairs, are aligned with a respective large perforation. 
     
     
         13 . The cell according to  claim 1 , wherein an area of the interior perforations constitutes a perforated area, and a ratio of the perforated area to the plate area is about 0.6. 
     
     
         14 . The cell according to  claim 1 , wherein the peripheral edge surrounds the plate area, except the tab area. 
     
     
         15 . The cell according to  claim 1 , wherein the partial perforations include two opposing corner perforations that are defined by a respective corner perforation edge, and each corner perforation edge being a part of the peripheral edge. 
     
     
         16 . The cell according to  claim 1 , wherein the partial perforations include a bottom perforation that is defined by a bottom perforation edge, and the bottom perforation edge being a part of the peripheral edge. 
     
     
         17 . The cell according to  claim 1 , wherein a thickness of the cathode current collector is in a range of about 0.060 millimeters to about 0.080 millimeters. 
     
     
         18 . The cell according to  claim 1 , wherein the cathode includes two cathodes that are each in the form of a pellet on opposing sides of the cathode current collector, and the peripheral edge, including the plurality of partial perforations, improves cohesion of the pellets to the cathode plate around the peripheral edge. 
     
     
         19 . The cell according to  claim 18 , wherein the cathode tab constitutes an alignment tab that serves to assist in alignment of the pellets to the cathode current collector, and the cathode tab including:
 a partially etched cut line that facilitates consistent pellet pressing, of the pellets upon the cathode current collector, in assembly of the cell.   
     
     
         20 . The cell according to  claim 1 , further including a header assembly that is attached to the housing and that includes pass through connections, and
 the cathode tab and the anode tab respectively connected to respective pass through connections, of the header assembly, so as to provide electrical connection exterior of the cell so as to electrically connect to the cell to a power consuming device.