Electrode assemblies for electrochemical cells

Claim 2

An electrochemical cell comprising: an aqueous alkaline electrolyte; an electrode assembly comprising, an electrically conductive metallic substrate defining an anode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous electrolyte, a layer of electrically insulating material having a plurality of perforations therethrough bonded to said anode face between said substrate and said anode, said perforations permitting electrical contact between said anode and said substrate; and a cathode spaced from said anode, said anode and said cathode being in mechanical contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 3

The electrochemical cell of claim 1 wherein said electrically insulating material is selected from the group consisting of polyvinyl chloride, acrylic resin, epoxy resin, plating stop-off paint, oxidized titanium, oxidized tantalum, and oxidized zirconium.

Claim 4

An electrochemical cell, comprising: an aqueous alkaline electrolyte; an electrode assembly comprising, an electrically conductive metallic substrate defining an anode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous electrolyte, a substantially continuous layer of a material which has a high hydrogen overvoltage relative to the metal of said substrate bonded to said substrate at said interface; and a cathode spaced from said anode, said anode and said cathode being in mechanical contact with said aqueous alakline electrolyte during operation of said cell.

Claim 5

An electrochemical cell, comprising: an aqueous alkaline electrolyte; an electrode assembly comprising, an electrically conductive metallic substrate defining an anode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous electrolyte, a substantially continuous layer of a material which has a high hydrogen overvoltage relative to the metal of said substrate bonded to said substrate at said interface; and a cathode spaced from said anode, said anode and said cathode being in mechanical contact with said aqueous alakline electrolyte during operation of said cell.

Claim 6

The electrochemical cell of claim 3 wherein said high overvoltage material is a metal selected from the group consisting of zinc, cadmium, indium, magnesium, aluminum, lead, copper and tin.

Claim 7

An electrochemical cell, comprising: an aqueous alkaline electrolyte; an electrode assembly comprising, an electrically conductive metallic substrate defining an anode face, wherein said substrate comprises a material which forms an electrically insulating film when exposed to said aqueous electrolyte, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous electrolyte; and a cathode spaced from said anode, said anode and said cathode being in mechanical contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 8

An electrochemical cell, comprising: an aqueous alkaline electrolyte; an electrode assembly comprising, an electrically conductive metallic substrate defining an anode face, wherein said substrate comprises a material which forms an electrically insulating film when exposed to said aqueous electrolyte, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous electrolyte; and a cathode spaced from said anode, said anode and said cathode being in mechanical contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 9

The electrochemical cell of claim 5 wherein said substrate comprises a metal selected from the group consisting of zirconium, titanium, magnesium, tantalum, calcium, beryllium, strontium, boron, niobium and yttrium.

Claim 10

An electrochemical cell, comprising: an aqueous alkaline electrolyte; an electrode assembly comprising, an electrically conductive metallic substrate defining an anode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous electrolyte, wherein an additive is present in said aqueous alkaline electrolyte, wherein said additive is deposited on said substrate forming an anode breakthrough coating thereon when said substrate is exposed to said aqueous alkaline electrolyte; and a cathode spaced from said anode, said anode and said cathode being in mechanical contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 11

An electrochemical cell, comprising: an aqueous alkaline electrolyte; an electrode assembly comprising, an electrically conductive metallic substrate defining an anode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous electrolyte, wherein an additive is present in said aqueous alkaline electrolyte, wherein said additive is deposited on said substrate forming an anode breakthrough coating thereon when said substrate is exposed to said aqueous alkaline electrolyte; and a cathode spaced from said anode, said anode and said cathode being in mechanical contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 12

An electrochemical cell in accordance with claims 1, 3, 5, or 7 wherein said reactive metal comprises an alkali metal.

Claim 13

The electrochemical cell of claim 8 wherein said alkali metal comprises lithium.

Claim 14

An electrochemical cell in accordance with claims 1, 3, 5, or 7 wherein said electrically conductive metallic substrate comprises nickel.

Claim 15

The electrochemical cell of claim 7 wherein said additive deposits as a material having a high hydrogen overvoltage relative to the metal of said substrate.

Claim 16

The electrochemical cell of claim 11 wherein said additive is selected from the group consisting of sodium stannate, potassium plumbate and potassium zincate.

Claim 17

The electrochemical cell of claim 7 wherein said additive comprises a cationic surfactant.

Claim 18

The electrochemical cell of claim 13 wherein said cationic surfactant comprises a fluorinated surfactant.

Claim 19

An electrochemical cell, comprising: an aqueous alkaline electrolyte; at least one bipo1ar e1ectrode assembly comprising, an electrically conductive metallic substrate defining an anode face and a cathode face on opposite sides thereof, a cathode disposed on said cathode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous alkaline electrolyte, a layer of electrically insulating material having a plurality of perforations therethrough bonded to said anode face between said substrate and said anode, said perforations permitting electrical contact between said anode and said substrate; and an anode end electrode and a cathode end electrode spaced from each other and said bipolar electrode assembly, said anode and said cathode of said bipolar assembly and said end electrodes being in contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 20

An electrochemical cell, comprising: an aqueous alkaline electrolyte; at least one bipo1ar e1ectrode assembly comprising, an electrically conductive metallic substrate defining an anode face and a cathode face on opposite sides thereof, a cathode disposed on said cathode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous alkaline electrolyte, a layer of electrically insulating material having a plurality of perforations therethrough bonded to said anode face between said substrate and said anode, said perforations permitting electrical contact between said anode and said substrate; and an anode end electrode and a cathode end electrode spaced from each other and said bipolar electrode assembly, said anode and said cathode of said bipolar assembly and said end electrodes being in contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 21

The electrochemical cell assembly of claim 15 wherein said electrically insulating material selected from the group consisting of polyvinyl chloride, arcylic resin, epoxy resin, plating stop-off paint, oxidized titanium, oxidized tantalum, and oxidized zirconium.

Claim 22

An electrochemical cell, comprising: an aqueous alkaline electrolyte; at least one bipolar electrode assembly comprising, an electrically conductive metallic substrate defining an anode face and a cathode face on opposite sides thereof, a cathode disposed on said cathode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous alkaline electrolyte, a substantially continuous layer of a material which has a high hydrogen overvoltage relative to the metal of said substrate bonded to said substrate at said interface; and an anode end electrode and a cathode end electrode spaced from each other and said bipolar electrode assembly, said anode and said cathode of said bipolar assembly and said end electrodes being in contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 23

An electrochemical cell, comprising: an aqueous alkaline electrolyte; at least one bipolar electrode assembly comprising, an electrically conductive metallic substrate defining an anode face and a cathode face on opposite sides thereof, a cathode disposed on said cathode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous alkaline electrolyte, a substantially continuous layer of a material which has a high hydrogen overvoltage relative to the metal of said substrate bonded to said substrate at said interface; and an anode end electrode and a cathode end electrode spaced from each other and said bipolar electrode assembly, said anode and said cathode of said bipolar assembly and said end electrodes being in contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 24

The electrochemical cell assembly of claim 17 wherein said high overvoltage material is a metal selected from the group consisting of zinc, cadmium, indium, magnesium, aluminum, lead, copper and tin.

Claim 25

An electrochemical cell, comprising: an aqueous alkaline electrolyte; at least one bipolar electrode assembly comprising, an electrically conductive metallic substrate defining an anode face and a cathode face on opposite sides thereof, wherein said substrate comprises a material which forms an electrically insulating film when exposed to said aqueous electrolyte, a cathode disposed on said cathode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous alkaline electrolyte; and an anode end electrode and a cathode end electrode spaced from each other and said bipolar electrode assembly, said anode and said cathode of said bipolar assembly and said end electrodes being in contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 26

An electrochemical cell, comprising: an aqueous alkaline electrolyte; at least one bipolar electrode assembly comprising, an electrically conductive metallic substrate defining an anode face and a cathode face on opposite sides thereof, wherein said substrate comprises a material which forms an electrically insulating film when exposed to said aqueous electrolyte, a cathode disposed on said cathode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous alkaline electrolyte; and an anode end electrode and a cathode end electrode spaced from each other and said bipolar electrode assembly, said anode and said cathode of said bipolar assembly and said end electrodes being in contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 27

The electrochemical cell assembly of claim 19 wherein said substrate comprises a metal selected from the group consisting of zirconium, titanium, magnesium, tantalum, calcium, beryllium, strontium, boron, niobium and yttrium.

Claim 28

An electrochemical cell, comprising: an aqueous alkaline electrolyte; at least one bipolar electrode assembly comprising, an electrically conductive metallic substrate defining an anode face and a cathode face on opposite sides thereof, a cathode disposed on said cathode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous alkaline electrolyte, wherein an additive is present in said aqueous alkaline electrolyte, wherein said additive is deposited on said substrate forming an anode breakthrough coating thereon when said substrate is exposed to said aqueous alkaline electrolyte; and an anode end electrode and a cathode end electrode spaced from each other and said bipolar electrode assembly, said anode and said cathode of said bipolar assembly and said end electrodes being in contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 29

An electrochemical cell, comprising: an aqueous alkaline electrolyte; at least one bipolar electrode assembly comprising, an electrically conductive metallic substrate defining an anode face and a cathode face on opposite sides thereof, a cathode disposed on said cathode face, an anode disposed on and in electrical contact with said anode face and defining an interface therewith, said anode comprising a metal reactive in the presence of said aqueous alkaline electrolyte, wherein an additive is present in said aqueous alkaline electrolyte, wherein said additive is deposited on said substrate forming an anode breakthrough coating thereon when said substrate is exposed to said aqueous alkaline electrolyte; and an anode end electrode and a cathode end electrode spaced from each other and said bipolar electrode assembly, said anode and said cathode of said bipolar assembly and said end electrodes being in contact with said aqueous alkaline electrolyte during operation of said cell.

Claim 30

The electrochemical cell assembly of claim 21 wherein said additive deposits as a material having a high hydrogen overvoltage relative to the metal of said substrate.

Claim 31

The electrochemical cell assembly of claim 22 wherein said additive is selected from the group consisting of sodium stannate, potassium plumbate and potassium zincate.

Claim 32

The electrochemical cell assembly of claim 21 wherein said additive comprises a cationic surfactant.

Claim 33

The electrochemical cell assembly of claim 24 wherein said cationic surfactant comprises a fluorinated surfactant.

Claim 34

An electrochemical cell in accordance with claims 15, 17, 19, or 21 wherein said reactive metal comprises an alkali metal.

Claim 35

The electrochemical cell assembly of claim 26 wherein said alkali metal comprises a lithium.

Claim 36

An electrochemical cell in accordance with claims 15, 17, 19 or 21 wherein said cathode comprises silver oxide.

Claim 37

An electrochemical cell in accordance with claims 15, 17, 19 or 21 wherein said electrically conductive metallic substrate comprises nickel.