Electrochemical cell and cathode for same

Claim 2

A self-supporting cathode structure for use in an electrochemical cell comprising: a rigid, electrically conductive, T-shaped frame member; an electrically conductive generally planar substrate having a plurality of interstice-defining members and affixed about its periphery to the leg of the T-shaped frame member; and an aggregate of discrete, porous carbon conglomerates impressed on the interstice-defining members of the substrate from opposite sides of the substrate and being in mutual physical and electrical contact through the interstices, a network of electrolyte-conducting channels extending throughout the resulting porous carbon structure; the interstice-defining member of the substrate electrically contacting the interior of the porous carbon structure throughout the porous carbon structure to function as a current collector for the cathode.

Claim 3

The cathode structure of claim 1 wherein the substrate is an expanded metal screen.

Claim 4

The cathode structure of claim 2 wherein the porous carbon structure comprises an aggregate of discrete porous globules defining the electrolyte-conducting channels therebetween.

Claim 5

The cathode structure of claim 3 wherein the globules are in the order of 0.1 to 15mm in length.

Claim 6

An electrochemical cell comprising: a case; first and second terminals located on the exterior of the case; means for electrically insulating the second terminal from the first terminal; an anode structure within the case and electrically connected to the first terminal; a self-supporting cathode structure formed from: a rigid, electrically conductive, T-shaped frame member electrically connected to the second terminal, an electrically conductive generally planar substrate having a plurality of interstice-defining members and affixed about its periphery to the leg of the T-shaped frame member, and an aggregate of discrete, porous carbon conglomerates impressed on the interstice-defining members of the substrate from opposite sides of the substrate and being in mutual physical and electrical contact through the interstices, a network of electrolyte-conducting channels extending throughout the resulting porous carbon structure, the interstice-defining members of the substrate electrically contacting the interior of the porous carbon structure throughout the porous carbon structure to function as a current collector for the cathode; an electrolytic solution including a cathode depolarizer that is electrochemically reduced on the porous carbon structure; and a porous separator of non-conductive material disposed between the anode and cathode structure.

Claim 7

An electrochemical cell comprising: a case; first and second terminals located on the exterior of the case; means for electrically insulating the second terminal from the first terminal; an anode structure within the case and electrically connected to the first terminal; a self-supporting cathode structure formed from: a rigid, electrically conductive, T-shaped frame member electrically connected to the second terminal, an electrically conductive generally planar substrate having a plurality of interstice-defining members and affixed about its periphery to the leg of the T-shaped frame member, and an aggregate of discrete, porous carbon conglomerates impressed on the interstice-defining members of the substrate from opposite sides of the substrate and being in mutual physical and electrical contact through the interstices, a network of electrolyte-conducting channels extending throughout the resulting porous carbon structure, the interstice-defining members of the substrate electrically contacting the interior of the porous carbon structure throughout the porous carbon structure to function as a current collector for the cathode; an electrolytic solution including a cathode depolarizer that is electrochemically reduced on the porous carbon structure; and a porous separator of non-conductive material disposed between the anode and cathode structure.