An alkaline electrochemical cell has a central cathode having a corresponding cathode current collector electrically connected with a positive terminal of the electrochemical cell. The cathode current collector has a tubular shape, such as a cylindrical shape or rectangular shape, extending parallel with the length of the central cathode. The cathode current collector is embedded within the central cathode, such as at a medial point of a radius of the central cathode, thereby minimizing the distance between the cathode current collector and any portion of the central cathode, thereby increasing the mechanical strength of the cathode and facilitating charge transfer to the cathode current collector.

Embodiments described herein relate generally to electrochemical cells having semi-solid electrodes that are coated on only one side of a current collector. In some embodiments, an electrochemical cell includes a semi-solid positive electrode coated on only one side of a positive current collector and a semi-solid negative electrode coated on only one side of a negative current collector. A separator is disposed between the semi-solid positive electrode and the semi-solid negative electrode. At least one of the semi-solid positive electrode and the semi-solid negative electrode can have a thickness of at least about 250 m.

A separator for a bobbin-style electrochemical cell is inserted into an interior opening within a ring-shaped cathode in an electrochemical cell can. An expansion force is then applied to an interior surface of the separator to press the separator against the interior walls of the cathode. A tool may then remove various creases and/or wrinkles in the separator and/or may then heat seal at least a portion of the tubular walls of the separator to minimize the void space between the separator and active material (e.g., cathode and/or anode) within the electrochemical cell.

Embodiments described herein relate generally to electrochemical cells having semi-solid electrodes that are coated on only one side of a current collector. In some embodiments, an electrochemical cell includes a semi-solid positive electrode coated on only one side of a positive current collector and a semi-solid negative electrode coated on only one side of a negative current collector. A separator is disposed between the semi-solid positive electrode and the semi-solid negative electrode. At least one of the semi-solid positive electrode and the semi-solid negative electrode can have a thickness of at least about 250 m.

Disclosed is a pouch-type secondary battery, which includes an electrode assembly having a positive electrode plate and a negative electrode plate disposed to face each other and a pouch case having a concave groove formed to accommodate the electrode assembly, wherein the pouch case includes a first pouch film and a second pouch film thermally fused to the first pouch film, and wherein a concave groove is formed in at least one of the first pouch film and the second pouch film, and the concave groove has a bottom surface on which the electrode assembly is placed so that the bottom surface has an area equal to or greater than an area of a reference surface that covers an opening of the concave groove.

A battery includes a battery case including a housing having side walls defining a first open end and a second open end, the battery case including a separate top cover to cover the first open end of the housing and a separate bottom cover to cover the second open end of the housing; a first electrode located within the case; a second electrode located within the case; a first terminal coupled to the first electrode and exposed outside the case; and a second terminal coupled to the second electrode and exposed outside the case.

A separator for a bobbin-style electrochemical cell is inserted into an interior opening within a ring-shaped cathode in an electrochemical cell can. An expansion force is then applied to an interior surface of the separator to press the separator against the interior walls of the cathode. A tool may then remove various creases and/or wrinkles in the separator and/or may then heat seal at least a portion of the tubular walls of the separator to minimize the void space between the separator and active material (e.g., cathode and/or anode) within the electrochemical cell.

An alkaline electrochemical cell has a central cathode having a corresponding cathode current collector electrically connected with a positive terminal of the electrochemical cell. The cathode current collector has a tubular shape, such as a cylindrical shape or rectangular shape, extending parallel with the length of the central cathode. The cathode current collector is embedded within the central cathode, such as at a medial point of a radius of the central cathode, thereby minimizing the distance between the cathode current collector and any portion of the central cathode, thereby increasing the mechanical strength of the cathode and facilitating charge transfer to the cathode current collector.

The present disclosure is directed to electrochemical cells having injection molded or 3D printed components, such as cathodes, anodes, and/or electrolytes, and methods for making such electrochemical cells. The cathodes, anodes, and/or electrolytes can be formed from a binder resin and various conductive and active materials, mixtures of which are injected into a mold under heat and pressure to form the components of the electrochemical cells. The cathode can include conductive metallic powder, flakes, ribbons, fibers, wires, and/or nanotubes. Further, electrochemical arrays can be formed from multiple electrochemical cells having injection molded or 3D printed components.

The present invention provides an aqueous electrolyte for use in rechargeable zinc-halide storage batteries that possesses improved stability and durability and improves zinc-halide battery performance. One aspect of the present invention provides an electrolyte for use in a secondary zinc bromine electrochemical cell comprising from about 30 wt % to about 40 wt % of ZnBr.sub.2 by weight of the electrolyte; from about 5 wt % to about 15 wt % of KBr; from about 5 wt % to about 15 wt % of KCl; and one or more quaternary ammonium agents, wherein the electrolyte comprises from about 0.5 wt % to about 10 wt % of the one or more quaternary ammonium agents.