Various embodiments are directed to an electrochemical cell having a non-homogeneous anode. The electrochemical cell includes a container, a cathode forming a hollow cylinder within the container, an anode positioned within the hollow cylinder of the cathode, and a separator between the cathode and the anode. The anode defines a characteristic gradient between an interior portion of the anode and the outermost surface of the anode adjacent the separator. The characteristic gradient may be defined as, for example, an average active material particle size within the anode that changes as a function of the radial location within the anode or a surfactant concentration gradient that changes as a function of the radial location within the anode.

A seal assembly for a battery cell comprises a cross-linked grommet having an opening. A current collector has a head and a stem extending from the head, the stem and the grommet forming an interference fit at the opening. The grommet comprises a cross-linked polymer. A method of manufacturing a battery cell with a cross-linked grommet comprises forming a grommet comprising a precursor polymer material, thereby forming a pre-formed grommet, exposing the pre-formed grommet comprising the precursor polymer material to a cross-linking treatment, thereby forming a cross-linked grommet, and incorporating the cross-linked grommet in a battery cell.

An alkaline electrochemical cell includes a cathode, an anode which includes an anode active material, and a non-conductive separator disposed between the cathode and the anode, wherein from about 20% to about 50% by weight of the anode active material relative to a total amount of anode active material has a particle size of less than about 75 μm, and wherein the separator includes a unitary, cylindrical configuration having an open end, a side wall, and integrally formed closed end disposed distally to the open end.

Alkaline electrochemical cells are provided, wherein dissolved zinc oxide or zinc hydroxide is included at least in the free electrolyte solution, and/or solid zinc oxide or zinc hydroxide is included in the anode, so as to slow formation of a zinc oxide passivation layer on a zinc electrode. Methods for preparing such cells are also provided.

Various embodiments are directed to an electrochemical cell having a non-homogeneous anode. The electrochemical cell includes a container, a cathode forming a hollow cylinder within the container, an anode positioned within the hollow cylinder of the cathode, and a separator between the cathode and the anode. The anode comprises at least two concentric anode portions, defined by different anode characteristics. For example, the two anode portions may contain different surfactant types, which provides the two anode portions with different charge transfer resistance characteristics. By lowering the charge transfer resistance of a portion of an anode located proximate the current collector of the cell (and away from the separator) relative to an anode portion located adjacent the separator, improved cell discharge performance may be obtained.

An alkaline electrochemical cell includes a cathode, an anode which includes an anode active material, and a non-conductive separator disposed between the cathode and the anode, wherein from about 20% to about 50% by weight of the anode active material relative to a total amount of anode active material has a particle size of less than about 75 μm, and wherein the separator includes a unitary, cylindrical configuration having an open end, a side wall, and integrally formed closed end disposed distally to the open end.

A gelled anode for an alkaline electrochemical cell contains zinc-based particles, an alkaline electrolyte, a gelling agent, and two or more additives selected from the group consisting of an alkali metal hydroxide, an organic phosphate ester surfactant, a metal oxide, and tin, which as reduced cell gassing properties relative to cells lacking such additives.

An alkaline dry battery includes a battery case, a hollow cylindrical positive electrode accommodated in the battery case, a negative electrode disposed in the hollow portion of the positive electrode, a separator disposed between the positive electrode and the negative electrode, and an electrolytic solution contained in the positive electrode, the negative electrode and the separator. The alkaline dry battery further includes a layer principally including a compound containing a polyoxyethylene group between the positive electrode and the inner surface of the battery case.

An alkaline battery includes a tubular battery case, a positive electrode filled in the battery case and including a stack of n pieces of hollow tubular pellets, a negative electrode disposed in hollow portions of the pellets, a separator disposed between the positive electrode and the negative electrode, and an alkaline electrolytic solution. The battery case includes a body portion having a thickness of 0.15 mm or less. The positive electrode contains manganese dioxide and a conductive agent, and n is an integer of 3 or more. First resistance is higher than second resistance, where the first resistance is resistance of at least one pellet positioned in a middle portion in a height direction of the stack, and the second resistance is resistance of at least one pellet positioned in end portions in the height direction of the stack.

An electrochemical cell comprises a can comprising a cylindrical side wall extending from a closed end wall. The closed end wall comprises a protrusion. The protrusion has a protrusion cavity therein. A pre-formed pellet of a first electrode material is disposed in the protrusion cavity. The electrochemical cell may further comprise a separator defining an inner cavity and separating the inner cavity from an outer cavity. The outer cavity is defined by the can and the separator. The electrochemical cell may further comprise a first electrode material disposed in the outer cavity; and a second electrode material disposed in the inner cavity.