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An insulator structure forming a physical barrier encapsulating the entire electrode assembly including all the positive portions and segregating them from the negative leads and the casing is described. By completely encapsulating the electrode assembly including the cathode lead portions from the

An insulator structure forming a physical barrier encapsulating the entire electrode assembly including all the positive portions and segregating them from the negative leads and the casing is described. By completely encapsulating the electrode assembly including the cathode lead portions from the anode leads and the casing, no opposite polarity structures that can potentially serve as a surface for lithium bridging are left exposed to electrolyte.

대표청구항 ▼

What is claimed is: 1. An electrochemical cell, which comprises: a) a casing comprising a first casing portion secured to a second casing portion to form an enclosure; b) an electrode assembly housed inside the casing and comprised of an anode comprising lithium and a cathode, wherein the anode com

What is claimed is: 1. An electrochemical cell, which comprises: a) a casing comprising a first casing portion secured to a second casing portion to form an enclosure; b) an electrode assembly housed inside the casing and comprised of an anode comprising lithium and a cathode, wherein the anode comprises at least one anode lead electrically connected to the casing as its terminal and the cathode comprises at least one cathode lead electrically connected to a terminal lead insulated from the casing; c) an insulator comprising a first insulator portion partially housed inside a second, outer insulator portion to completely envelope the electrode assembly, wherein the second, outer insulator portion comprises a plurality of spaced apart raised ribs, each having a crest contacting an interior surface of the casing where the first casing portion is secured to the second casing portion with intermediate lands between the plurality of raised ribs contacting the first insulator portion opposite the location where the first casing portion is secured to the second casing portion; and d) an electrolyte provided in the casing to activate the electrode assembly. 2. The electrochemical cell of claim 1 wherein the insulator further surrounds the at least one cathode lead. 3. The electrochemical cell of claim 1 wherein the casing is of a deep drawn type closed by a lid or of a first and a second mating members. 4. The electrochemical cell of claim 1 wherein either the anode or the cathode is relatively elongated and provided in a serpentine shape with plates of the other of the anode and cathode interleaved between folds of the serpentine. 5. The electrochemical cell of claim 1 wherein the anode is relatively elongated and provided in a serpentine shape with at least two cathode plates interleaved and joined together in a butterfly configuration by a butterfly connector connected to the terminal lead. 6. The electrochemical cell of claim 5 wherein there are at least three cathode plates, two of which are interleaved and joined together in a butterfly configuration by the connector, the other having a manifold tab that contacts the butterfly connector and connects to the terminal lead. 7. The electrochemical cell of claim 1 wherein the electrode assembly comprises at least one anode plate and at least one cathode plate. 8. The electrochemical cell of claim 1 wherein the at least one cathode lead is supported in a ferrule by an electrically insulating material, the ferrule being electrically connected to the casing. 9. The electrochemical cell of claim 8 wherein a polymeric shield surrounds the ferrule where the first insulator is partially housed inside the second insulator. 10. The electrochemical cell of claim 1 wherein the at least one anode lead is diametrically opposite the electrode assembly from the cathode lead. 11. The electrochemical cell of claim 1 wherein the cathode is of a cathode active material selected from the group consisting of silver vanadium oxide, copper silver vanadium oxide, manganese dioxide, cobalt oxide, nickel oxide, copper oxide, titanium disulfide, copper sulfide, iron sulfide, iron disulfide, copper vanadium oxide, carbon, fluorinated carbon, vanadium oxide, LiCoO2, LiNiO2, LiMn2O4, Ag2O, Ag2O2, CuF2, Ag2CrO4, and mixtures thereof. 12. The electrochemical cell of claim 1 wherein the insulator is of a material that is substantially impervious to lithium ion flow there through and selected from the group consisting of polyethylene, polypropylene, ETFE, PTFE, and polyethylenechlorotrifluoroethylene. 13. The electrochemical cell of claim 1 wherein the terminal lead is of molybdenum. 14. The electrochemical cell of claim 13 wherein a proximal portion of the molybdenum terminal lead is provided with a titanium sleeve electrically connected to the at least one cathode lead. 15. An electrochemical cell, which comprises: a) a casing comprising a first casing portion comprising a first major face wall joined to a first surrounding side wall and a second casing portion comprising a second major face wall joined to a second surrounding side wall, wherein the first and second casing members are matable to each other at their respective first and second surrounding side walls to form a seam; b) an electrode assembly housed inside the casing and comprising an anode of lithium and a cathode, wherein the anode comprises at least one anode lead electrically connected to the casing as its terminal and the cathode comprises at least one cathode lead electrically connected to a terminal lead insulated from the casing; c) an insulator comprising a first insulator portion partially housed inside a second, outer insulator portion to isolate the electrode assembly including the at least one cathode lead from the casing, wherein the second, outer insulator portion comprises a plurality of spaced apart raised ribs, each having a crest contacting an interior surface of the casing at the seam of the casing portions with intermediate lands between the plurality of raised ribs contacting the first insulator portion opposite the seam of the first casing portion mated to the second casing portion; and d) an electrolyte provided in the casing to activate the electrode assembly. 16. A method for preventing the formation of lithium clusters in an electrochemical cell, comprising the steps of: a) providing a casing comprising a first casing portion closable by a second casing portion; b) providing an electrode assembly comprising an anode of lithium and a cathode, wherein the anode comprises at least one anode lead electrically connectable to the casing and the cathode comprises at least one cathode lead electrically connectable to a terminal lead insulated from the casing; c) providing an insulator comprising a first insulator portion partially housed inside a second, outer insulator portion and completely enveloping the electrode assembly including the at least one cathode lead; d) housing the electrode assembly enveloped inside the insulator in the first casing portion; e) electrically connecting the at least one anode lead to the first casing portion as the anode terminal and electrically connecting the at least one cathode lead to the terminal lead insulated from the first casing portion; f) closing the first casing portion with the second casing portion to provide the casing housing the electrode assembly, wherein the second, outer insulator portion comprises a plurality of spaced apart raised ribs, each having a crest contacting an interior surface of the casing where the first casing portion meets and closes the second casing portion with intermediate lands between the plurality of raised ribs contacting the first insulator portion opposite the meeting location of the first and second casing portions; and g) activating the electrode assembly with an electrolyte provided in the casing. 17. The method of claim 16 including providing the casing being of a deep drawn type closed by a lid or of a first and a second mating members. 18. The method of claim 16 including providing either the anode or the cathode being relatively elongated and provided in a serpentine shape and further interleaving plates of the other of the anode and cathode between folds of the serpentine. 19. The method of claim 16 including providing the insulator of a polymeric material that is substantially impervious to lithium ion flow there through and selected from the group consisting of polyethylene, polypropylene, ETFE, PTFE, and polyethylenechlorotrifluoroethylene. 20. The method of claim 16 including providing the at least one anode lead being diametrically opposite the electrode assembly from the cathode lead. 21. The method of claim 16 including the insulator inhibiting fluid flow communication of the electrolyte between the electrode assembly and the at least one anode lead connected to the casing to an extent sufficient to prevent conditions favorable for the formation of lithium clusters between the electrode assembly and the at least one anode lead connected to the casing. 22. The electrochemical cell of claim 1 wherein the insulator inhibits fluid flow communication of the electrolyte between the electrode assembly and the at least one anode lead connected to the casing. 23. The electrochemical cell of claim 15 wherein the insulator inhibits fluid flow communication of the electrolyte between the electrode assembly and the at least one anode lead connected to the casing.