Claims
- 1. A pressure vessel comprising an outer housing; said housing having a closed end and opposing open end; said vessel further comprising an end cap assembly sealing the open end of said housing, said outer housing and said end cap assembly forming a pressure boundary surface around the vessel interior;
wherein said end cap assembly has an aperture therein and a sealing member for sealing said aperture, wherein at least a portion of said sealing member is in a compressed state within said aperture; wherein said vessel comprises a vent mechanism located on said pressure boundary surface, wherein said vent mechanism activates to release gas pressure from within the vessel, said vent mechanism comprising a first rupture zone forming a groove on said boundary surface, said groove defining a material region thinner than the average thickness of said boundary; and a second rupture zone on said boundary surface, wherein said first rupture zone ruptures when gas pressure within the cell rises to a first pressure level and said second rupture zone ruptures when gas pressure within the cell rises to a second pressure level higher than said first pressure level.
- 2. The vessel of claim 1 wherein the cell's length between said closed end and open end defines the direction of the cell's central longitudinal axis, and wherein said sealing member comprises a plastic material being compressed at least in a direction about perpendicular to said central longitudinal axis.
- 3. The vessel of claim 1 wherein said first and second rupture zones are spaced apart on said boundary surface.
- 4. The vessel of claim 1 wherein said first rupture zone ruptures when gas pressure within the vessel rises to a pressure between about 250 and 800 psig (1724×103 and 5515×103 pascal gage).
- 5. The vessel of claim 1 wherein said first rupture zone ruptures when gas pressure within the vessel rises to a pressure between about 400 and 800 psig (2758×103 and 5515×103 pascal gage).
- 6. The vessel of claim 1 wherein said second rupture zone ruptures when gas pressure within the vessel reaches a pressure between about 800 and 2500 psig (5515×103 and 17235×103 pascal gage).
- 7. The vessel of claim 1 wherein the second rupture zone comprises a laser weld within a portion of said boundary surface.
- 8. The vessel of claim 1 wherein said groove is formed by stamping said boundary surface.
- 9. The vessel of claim 7 wherein said laser weld is formed between said housing and a metal member fitted within the open end of said housing thereby closing said open end.
- 10. The vessel of claim 7 wherein said laser weld is formed between the inside surface of said housing and the edge of a metal member fitted within the open end of said housing thereby closing said open end.
- 11. The vessel of claim 7 wherein said laser weld is made by a Nd:Yag laser and said laser weld ruptures when gas pressure within the cell rises to a level of between about 800 and 2500 psig (5515×103 and 17235×103 pascal gage).
- 12. The vessel of claim 9 wherein said vessel has a cuboid shape and said metal member is a rectangular metal plate.
- 13. The vessel of claim 9 wherein said aperture is within said metal member and said compressed sealing member is within said aperture.
- 14. The vessel of claim 13 wherein said metal member comprises a plate having an integrally formed sleeve extending therefrom, wherein said sleeve surrounds a portion of said sealing member and holds said portion of said sealing member in a compressed state.
- 15. The vessel of claim 14 wherein said sealing member comprises plastic material and said sealing member is compressed in a direction perpendicular to the cell's central longitudinal axis.
- 16. The vessel of claim 14 further comprising an elongated metal member inserted into said aperture so that a portion of said seal member is sandwiched between said elongated metal member and said metal sleeve so that said portion of said seal member is held in compressed state therebetween.
- 17. The vessel of claim 15 wherein said sealing member is also compressed in a direction parallel to the cell's central longitudinal axis.
- 18. A primary alkaline cell comprising a negative and a positive terminal, an anode and a cathode, and an outer housing comprising at least one side being at least substantially flat, said housing having a closed end and opposing open end, said cell further comprising an end cap assembly sealing the open end of said housing; wherein said outer housing and said end cap assembly forms a pressure boundary surface around the cell interior; wherein said end cap assembly has an aperture therein and an insulating seal member for sealing said aperture, wherein at least a portion of said sealing member is in a compressed state within said aperture.
- 19. The alkaline cell of claim 18 wherein the cell's length is between said closed end and open end defining the direction of the cell's central longitudinal axis, and wherein said sealing member comprises a plastic material being compressed in a direction about perpendicular to said central longitudinal axis.
- 20. The alkaline cell of claim 19 wherein the cell further comprises an anode comprising zinc and a cathode comprising at least one of MnO2 and nickel oxyhydroxide within said housing, and a separator between said anode and cathode;
wherein said cell comprises a vent mechanism located on said boundary surface, wherein said vent mechanism activates to release gas pressure from within the cell as said gas pressure rises, said vent mechanism comprising a first rupture zone comprising a groove on said boundary surface, said groove defining an underlying material region thinner than the average thickness of said boundary; and a second rupture zone on said boundary surface, wherein the first zone ruptures when gas pressure within the cell rises to a first pressure level and said second zone ruptures when gas pressure within the cell rises to a second pressure level being higher than said first pressure level allowing gas from within the cell to escape from the cell interior through said ruptures.
- 21. The alkaline cell of claim 20 wherein the cathode comprises a plurality of rectangular shaped cathode slabs; wherein each of said slabs has a central opening devoid of cathode material; wherein said cathode slabs are stacked within the housing so that said openings devoid of cathode material form a core, with the outer surface of said cathode contacting the inside surface of said housing.
- 22. The alkaline cell of claim 18 wherein said outer housing is of cuboid shape.
- 23. The alkaline cell of claim 20 wherein said first and second rupture zones are spaced apart on said boundary surface.
- 24. The alkaline cell of claim 20 wherein said first rupture zone ruptures when gas pressure within the vessel rises to a pressure between about 250 and 800 psig (1724×103 and 5515×103 pascal gage).
- 25. The alkaline cell of claim 20 wherein said first rupture zone ruptures when gas pressure within the vessel rises to a pressure between about 400 and 800 psig (2758×103 and 5515×103 pascal gage).
- 26. The alkaline cell of claim 20 wherein said second rupture zone ruptures when gas pressure within the vessel reaches a pressure between about 800 and 2500 psig (5515×103 and 17235×103 pascal gage).
- 27. The alkaline cell of claim 20 wherein the second rupture zone comprises a laser weld within a portion of said boundary surface.
- 28. The alkaline cell of claim 20 wherein said groove is formed by stamping said boundary surface.
- 29. The alkaline cell of claim 27 wherein said end cap assembly comprises a metal cover and said laser weld is formed between said housing and a said metal cover fitted within the open end of said housing thereby closing said open end.
- 30. The alkaline cell of claim 27 wherein said end cap assembly comprises a metal cover and said laser weld is formed between the inside surface of said housing and the edge of a metal cover fitted within the open end of said housing thereby closing said open end.
- 31. The alkaline cell of claim 27 wherein said laser weld is formed by a Nd:Yag laser and said laser weld ruptures when gas pressure within the cell rises to a level of between about 800 and 2500 psig (5515×103 and 17235×103 pascal gage).
- 32. The alkaline cell of claim 29 wherein said metal cover comprises a metal plate having an aperture therethrough.
- 33. The alkaline cell of claim 29 wherein said metal cover comprises a rectangular plate having an aperture therethrough.
- 34. The alkaline cell of claim 32 wherein said aperture is within said metal cover and said compressed insulating seal member is within said aperture.
- 35. The alkaline cell of claim 34 wherein said metal cover comprises a plate having an integrally formed sleeve extending therefrom, wherein said sleeve surrounds a portion of said insulating seal member and holds said portion of said seal member in a compressed state.
- 36. The alkaline cell of claim 34 wherein said sealing member comprises plastic material and said sealing member is compressed in a direction perpendicular to the cell's central longitudinal axis.
- 37. The alkaline cell of claim 32 wherein said end cap assembly comprises said metal cover, a terminal end plate, an insulating seal member, and an elongated electrically conductive member having a portion thereof passing through both said insulating seal member and said metal cover, wherein said elongated conductive member has a head electrically connected to said terminal end plate.
- 38. The alkaline cell of claim 37 wherein said electrically conductive member is electrically connected to said anode.
- 39. The alkaline cell of claims 38 wherein a portion of said elongated conductive member penetrates into said anode and functions as an anode current collector.
- 40. The alkaline cell of claim 37 wherein said metal cover comprises a plate having an integrally formed sleeve extending therefrom, wherein said sleeve surrounds a portion of said insulating seal member and holds said portion of said insulating seal member in a compressed state.
- 41. The alkaline cell of claim 40 wherein said insulating seal member comprises an integrally formed central boss having a side wall defining a cavity therein, said boss being held within said metal cover sleeve in interference fit therewith.
- 42. The alkaline cell of claim 41 wherein a portion of said elongated conductive member is held within said insulating boss cavity in interference fit therewith, so that at least a portion of said boss side wall is held compressed between said metal cover sleeve and said elongated conductive member.
- 43. The alkaline cell of claim 42 wherein with the percentage compression of the insulating seal boss side wall thickness defined as ΔR % and the length of the interface between said metal cover sleeve and said insulating boss side wall as L (mm), then the product of ΔR % multiplied by L is between about 0.04 and 240.
- 44. The alkaline cell of claim 42 wherein said insulating seal member is also compressed in a direction parallel to the cell's central longitudinal axis.
- 45. The alkaline cell of claim 44 wherein at least a portion of said insulating seal member is held compressed between the head of said elongated conductive member and an integrally formed flange protruding from said elongated conductive member and abutting a surface of said insulating seal member.
- 46. The alkaline cell of claim 38 wherein said end cap assembly further comprises an electrically insulating member between said terminal end plate and said metal cover thereby insulating said terminal end plate from said metal cover.
- 47. The alkaline cell of claim 46 wherein said electrically insulating member between said terminal end plate and said metal cover comprises a plastic material.
- 48. The alkaline cell of claim 46 wherein said electrically insulating member between said terminal end plate and said metal cover comprises paper material.
- 49. The alkaline cell of claim 46 wherein said terminal end plate has a central area of smaller thickness than the average thickness of said end plate, wherein said elongated conductive member is welded by electrical resistance welding to said terminal end plate at said central area.
- 50. The alkaline cell of claim 42 wherein sealant material comprising asphalt is applied between at least a portion of the surface of said elongated conductive member and said insulating boss to prevent leakage of alkaline electrolyte therethrough.
- 51. The alkaline cell of claim 42 wherein sealant material comprising asphalt is applied between at least a portion of the surface of said insulating boss and said metal cover sleeve to prevent leakage of alkaline electrolyte therethrough.
- 52. The alkaline cell of claim 21 wherein at least a portion of said central opening within said cathode slabs forms a cavity for housing said anode.
- 53. The alkaline cell of claim 52 wherein said cavity has an oblong configuration.
- 54. The alkaline cell of claim 20 wherein the cell comprises alkaline electrolyte comprising an aqueous solution of potassium hydroxide.
- 55. The alkaline cell of claim 54 wherein the cell is balanced so that the cathode is in excess such that the ratio of theoretical capacity of the MnO2 based on a theoretical specific value of 370 mamp-hr per gram MnO2, divided by the mAmp-hr capacity of zinc based on a theoretical specific value of 820 mAmp-hr per gram zinc, is between about 1.2 and 2.0.
- 56. The alkaline cell of claim 54 wherein the cell is balanced so that the cathode is in excess such that the ratio of theoretical capacity of the MnO2 based on a theoretical specific value of 370 mAmp-hr per gram MnO2, divided by the mAmp-hr capacity of zinc based on a theoretical specific value of 820 mamp-hr per gram zinc, is between about 1.4 and 1.8.
- 57. The alkaline cell of claim 18 wherein said cell has an overall thickness of between about 5 and 10 mm, wherein said overall thickness is defined as the distance between the outside surface of opposing sides of said housing defining the short dimension of said housing.
- 58. The alkaline cell of claim 18 wherein the housing comprises metal having a wall thickness of between about 0.30 mm and 0.50 mm.
- 59. The alkaline cell of claim 18 wherein the housing comprises metal having a wall thickness of between about 0.30 mm and 0.40 mm.
- 60. The alkaline cell of claim 18 wherein said housing comprises steel.
- 61. A primary alkaline cell comprising a negative and a positive terminal, and an outer housing, said housing having a closed end and opposing open end, said cell further comprising an anode and a cathode within said housing, a separator between said anode and cathode, and an end cap assembly sealing the open end of said housing thereby forming a boundary surface around the cell interior; wherein said end cap assembly comprises a metal cover at the open end of said housing and a weld formed between said housing and said metal cover to close said open end;
wherein said end cap assembly has an aperture therein and an insulating seal member for sealing said aperture, wherein at least a portion of said sealing member is in a compressed state within said aperture.
- 62. The alkaline cell of claim 61 wherein the anode comprises zinc and the cathode comprises manganese dioxide and said cathode comprises a plurality of rectangular shaped cathode slabs; wherein each of said slabs has a central opening devoid of cathode material; wherein said cathode slabs are stacked within the housing along the cell's central longitudinal axis so that said openings devoid of cathode material form a central core along said longitudinal axis, with the outer surface of said cathode contacting the inside surface of said housing.
- 63. The alkaline cell of claim 61 wherein the cell's length is between said closed end and open end defining the direction of the cell's central longitudinal axis, and wherein said sealing member comprises a plastic material being compressed in a direction about perpendicular to said central longitudinal axis.
- 64. The alkaline cell of claim 61 wherein said cell comprises a vent mechanism located on said boundary surface, wherein said vent mechanism activates to release gas pressure from within the cell as said gas pressure rises, said vent mechanism comprising a first rupture zone comprising a groove on said boundary surface, said groove defining an underlying material region thinner than the average thickness of said boundary; and a second rupture zone on said boundary surface, wherein the first zone ruptures when gas pressure within the cell rises to a first pressure level and said second zone ruptures when gas pressure within the cell rises to a second pressure level being higher than said first pressure level allowing gas from within the cell to escape from the cell interior through said ruptures.
- 65. The cell of claim 64 wherein said first and second rupture zones are spaced apart on said boundary surface.
- 66. The cell of claim 64 wherein the second rupture zone comprises a laser weld within a portion of said boundary surface.
- 67. The cell of claim 64 wherein said groove is formed by stamping said boundary surface.
- 68. The cell of claim 64 wherein the first zone on said boundary surface ruptures when gas pressure within the cell interior reaches a pressure level between about 250 and 800 psig (1724×103 and 5515×103 pascal gage) and said second zone on said boundary surface ruptures when gas pressure within the cell interior reaches a pressure level between about 800 and 2500 psig (5515×103 and 17235×103 pascal gage).
- 69. The cell of claim 64 wherein the first zone on said boundary surface ruptures when gas pressure within the cell interior reaches a pressure level between about 400 and 800 psig (2758×103 and 5515×103 pascal gage) and said second zone on said boundary surface ruptures when gas pressure within the cell interior reaches a pressure level between about 800 and 2500 psig (5515×103 and 1724×103 pascal gage).
- 70. The cell of claim 64 wherein the first rupture zone is formed by a groove on the outside surface of said housing and the second rupture zone is formed by a laser weld between the edge of said metal cover and the inside surface of said housing thereby fixing said metal cover along a portion of its edge to the inside surface of said outer housing in proximity to the open end of said housing.
- 71. The cell of claim 70 wherein said end cap assembly comprises said metal cover, a terminal end plate, an insulating seal member, and an elongated electrically conductive member having a portion thereof passing through both said insulating seal member and said metal cover, wherein said elongated conductive member has a head electrically connected to said terminal end plate.
- 72. The alkaline cell of claim 71 wherein said metal cover comprises a plate having an integrally formed sleeve extending therefrom, wherein said sleeve surrounds a portion of said insulating seal member and holds said portion of said insulating seal member in a compressed state.
- 73. The alkaline cell of claim 72 wherein said insulating seal member comprises an integrally formed central boss having a side wall defining a cavity therein, said boss side wall being held within said metal cover sleeve in interference fit therewith.
- 74. The alkaline cell of claim 73 wherein a portion of said elongated conductive member is held within said insulating boss cavity in interference fit therewith, so that at least a portion of said boss side wall is held compressed between said metal cover sleeve and said elongated conductive member.
- 75. The alkaline cell of claim 74 wherein with the percentage compression of the insulating seal boss side wall thickness defined as ΔR % and the length of the interface between said metal cover sleeve and said insulating boss side wall as L (mm), then the product of ΔR % multiplied by L is between about 0.04 and 240.
- 76. The alkaline cell of claim 74 wherein said insulating seal member is also compressed in a direction parallel to the cell's central longitudinal axis.
- 77. The alkaline cell of claim 76 wherein at least a portion of said insulating seal member is held compressed between the head of said elongated conductive member and a integrally formed flange protruding from said elongated conductive member and abutting a surface of said insulating seal member.
- 78. The cell of claim 64 wherein said groove runs parallel to the closed end of the cell.
- 79. The alkaline cell of claim 61 wherein the housing comprises metal having a wall thickness of between about 0.30 mm and 0.50 mm.
- 80. The alkaline cell of claim 61 wherein said cell has an overall thickness of between about 5 and 10 mm, wherein said overall thickness is defined as the distance between the outside surface of opposing sides of said housing defining the short dimension of said housing.
- 81. The alkaline cell of claim 61 wherein said housing has at least one side being at least substantially flat.
- 82. The alkaline cell of claim 61 wherein said housing has a cuboid shape.
- 83. A primary alkaline cell comprising a negative and a positive terminal, an anode and a cathode, and an outer housing, said housing having a closed end and opposing open end, said cell further comprising an end cap assembly sealing the open end of said housing; wherein said outer housing and said end cap assembly forms a pressure boundary surface around the cell interior; wherein said end cap assembly has an aperture therein and said end cap assembly further has an insulating seal member for sealing said aperture; wherein at least a portion of said insulating seal member is in a compressed state within said aperture; wherein said end cap assembly comprises a metal plate having an integral metal sleeve extending therefrom; wherein a portion of said insulating seal member forms a compressed insulating wall within said sleeve; wherein an interface is formed between said sleeve and said compressed insulating wall; and wherein the percentage compression of the insulating wall thickness is defined as ΔR % and the length of the interface between said sleeve and said insulating wall is defined as L(mm), then the product of ΔR % multiplied by L is between about 0.04 and 240.
- 84. The alkaline cell of claim 83 wherein the length, L (mm), of said interface between said metal sleeve and said compressed insulating wall is between about 0.4 mm and 6 mm and the percentage compression of the insulating wall thickness, ΔR %, is between about 0.1 percent and 40 percent.
- 85. The alkaline cell of claim 83 wherein said outer housing comprises at least one side being substantially flat.
- 86. The alkaline cell of claim 83 wherein said insulating seal member has an aperture therethrough and said compressed insulating wall defines a circumferential boundary for said aperture, and wherein said end cap assembly further comprises an elongated anode current collector member having a portion passing through said aperture in said insulating seal member.
- 87. The alkaline cell of claim 86 wherein at least a portion of said insulating wall is held compressed between said anode current collector and said metal sleeve.
- 88. The alkaline cell of claim 86 wherein the metal plate has an aperture therethrough and said metal sleeve forms a boundary for said aperture in said plate.
- 89. The alkaline cell of claim 87 wherein said insulating seal member has a skirt extending from a surface thereof, said skirt surrounding at least a portion of the elongated current collector.
- 90. The alkaline cell of claim 89 wherein said insulating skirt reduces the rate of corrosion of the inside surface of said housing.
- 91. The alkaline cell of claim 83 wherein said insulating seal member comprises plastic material.
- 92. The alkaline cell of claim 83 wherein the edge of said metal plate is laser welded to the inside surface of said housing to close the open end thereof.
- 93. The alkaline cell of claim 87 wherein said insulating seal member comprises an integrally formed central boss having a circumferential side wall forming said compressed insulating wall, said boss being held within said metal sleeve in interference fit therewith, said side wall being compressed between said anode current collector and said sleeve.
- 93. The alkaline cell of claim 83 wherein said anode comprises zinc and said cathode comprises at least one of manganese dioxide and nickel oxyhydroxide.
- 94. The alkaline cell of claim 83 wherein said anode comprises zinc and said cathode comprises manganese dioxide.
- 95. The alkaline cell of claim 83 wherein the cell has a longitudinal axis running in the direction between said open and closed ends and the percentage compression of the insulating wall thickness is measured in a direction about perpendicular to said longitudinal axis.
- 96. The alkaline cell of claim 83 wherein said housing has a cuboid shape.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of application Ser. No. 10/722,879, filed Nov. 26, 2003, which is a continuation in part of application Ser. No. 10/414750 filed Apr. 16, 2003, which is a continuation in part of application Ser. No. 10/336261 filed Jan. 3, 2003.
Continuation in Parts (3)
|
Number |
Date |
Country |
Parent |
10722879 |
Nov 2003 |
US |
Child |
10863861 |
Jun 2004 |
US |
Parent |
10414750 |
Apr 2003 |
US |
Child |
10722879 |
Nov 2003 |
US |
Parent |
10336261 |
Jan 2003 |
US |
Child |
10414750 |
Apr 2003 |
US |