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 . An electrochemical cell comprising:
 a cathode;   an anode; and   a stepped header comprising a first step and a second step, and a first opening, a second opening, and a third opening, wherein
 an upper surface of the first step is disposed directly on a lower surface of the header and an upper surface of the second step is disposed directly on a lower surface of the first step, 
 the first opening has a length extending from an upper surface of the header, through a thickness of the header and a thickness of the first step, and to a bottom surface of the first step, and 
 the second opening and the third opening each have a length extending from an upper surface of the header, through the thickness of the header, the thickness of the first step, and a thickness of the second step, and to a bottom surface of the second step, wherein a first terminal pin for connection to a cathode tab portion extends through the length of the second opening and a second terminal pin for connection to an anode tab portion extends through the length of the third opening. 
   
     
     
         2 . The electrochemical cell of  claim 1 , wherein the first opening in the first step is configured for a ball seal. 
     
     
         3 . The electrochemical cell of  claim 1 , wherein the second opening and the third opening in the second step are configured for a glass seal. 
     
     
         4 . The electrochemical cell of  claim 1 , wherein the length of the first step is less than a length of the header, and a length of the second step is less than a length of the first step. 
     
     
         5 . The electrochemical cell of  claim 1 , wherein the entire upper surface of the first step is disposed directly on the lower surface of the header and the entire upper surface of the second step is disposed directly on a lower surface of the first step. 
     
     
         6 . The electrochemical cell of  claim 1 , wherein the electrochemical cell has an internal volume including an electrode, a separator, an electrolyte volume, and a void volume, and the electrolyte volume is in the range of 38 percent to 46 percent of the internal volume. 
     
     
         7 . The electrochemical cell of  claim 6 , wherein the electrolyte volume is in the range of about 40 percent to about 44 percent of the internal volume. 
     
     
         8 . The electrochemical cell of  claim 6 , wherein the electrolyte volume is in the range of about 41 percent to about 43 percent of the internal volume. 
     
     
         9 . The electrochemical cell of  claim 6 , wherein the electrolyte volume is about 42 percent of the internal volume. 
     
     
         10 . The electrochemical cell of  claim 6 , wherein the void volume is in the range of about 3 percent to about 9 percent of the internal volume. 
     
     
         11 . The electrochemical cell of  claim 6 , wherein the void volume is in the range of about 4 percent to about 8 percent of the internal volume. 
     
     
         12 . The electrochemical cell of  claim 6 , wherein the void volume is in the range of about 5 percent to about 7 percent of the internal volume. 
     
     
         13 . The electrochemical cell of  claim 6 , wherein the void volume is about 6 percent of the internal volume.