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 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 lithium primary battery comprising a positive electrode sheet, a negative electrode sheet, a separator disposed between the positive electrode sheet and the negative electrode sheet and an electrolyte. The positive electrode comprises a current collector for the positive electrode and an active material layer for the positive electrode coated on at least one surface of the current collector for the positive electrode. The active material layer for the positive electrode comprises an active material capable of deintercalating lithium ions. The negative electrode sheet comprises a copper foil, a nickel foil, a conductive carbon paper or a steel film.

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.

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 invention provides a thin, bendable, printed, layered primary battery structure without a battery separator. The battery includes a first layer including a printed positive electrode. A second layer includes a negative electrode material which may be a printed negative electrode or a metal foil negative electrode. An adhesive, UV-curable intermediate layer is adhered to the first layer on a first side of the intermediate layer and is adhered to the second layer on a second side of the intermediate layer. The intermediate layer includes a water-soluble electroactive material and a water-soluble viscosity-regulating polymer in an amount sufficient to render the intermediate layer adhesive. The intermediate layer also includes a water-insoluble polymer matrix having sufficient rigidity to prevent contact of the first layer and the second layer. A flexible package encases the first, second, and intermediate layers.

The present invention provides a thin, bendable, printed, layered primary battery structure without a battery separator. The battery includes a first layer including a printed positive electrode. A second layer includes a negative electrode material which may be a printed negative electrode or a metal foil negative electrode. An adhesive, UV-curable intermediate layer is adhered to the first layer on a first side of the intermediate layer and is adhered to the second layer on a second side of the intermediate layer. The intermediate layer includes a water-soluble electroactive material and a water-soluble viscosity-regulating polymer in an amount sufficient to render the intermediate layer adhesive. The intermediate layer also includes a water-insoluble polymer matrix having sufficient rigidity to prevent contact of the first layer and the second layer. A flexible package encases the first, second, and intermediate layers.

Cast components can improve the effectiveness of current state-of-the-art in thermal battery processing technology in terms of cost, labor, materials usage, and flexibility. Cast components can include cast cathodes, anodes, and separators.

Cast components can improve the effectiveness of current state-of-the-art in thermal battery processing technology in terms of cost, labor, materials usage, and flexibility. Cast components can include cast cathodes, anodes, and separators.

In some embodiments, a battery, a cathode for a battery, and a method for making a cathode and a battery are provided. The method comprises the steps of at least combining an electrode active material, one or more conductive diluents, a binder and a solvent to form an electrode active mixture having a first solvent to powder weight ratio, reducing a solvent to powder weight ratio to form a paste, feeding the paste into a plastic tube; and calendering the plastic tube. A dry cathode mixture is provided. The dry cathode mixture includes a cathode active material, a conductive diluent and a polymeric binder. A solvent is mixed with the dry mixture to form a slurry. Solvent is removed from the slurry to form a doughy composition. The doughy composition is calender sheeted to form a sheet. The sheet is baked at a temperature of 30 C. to 120 C. for 15 minutes to 6 hours to form a dry sheet. The dry sheet is cut into coupons. The coupons are pressed to form a pressed coupon. The pressed coupons are baked to form cathodes, by subjecting the pressed coupons to a temperature of 30 C. to 120 C. for at least one hour. The cathodes may be processed into batteries.