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US5656395A
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US
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Metal-air cathode and cell having a hardened current collecting substrate
Assignee: Spectrum Brands Inc
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Filing: 1995-06-07
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Granted: 1997-08-12
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Expires: 2015-06-07
Abstract
Abstract A metal current collecting substrate for an air cathode in an electrochemical metal air cell is provided for, wherein the substrate is hardened by one of the steps of sandblasting, shotblasting, plastic deformation of the substrate below the recrystallization temperature range of the metal thereof, and heating the substrate to above the transformation temperature of the metal thereof followed by quenching the substrate below the transformation temperature of the metal thereof. Catalytically active materials, most preferably a mixture of carbon and manganese dioxide, are pressed or otherwise disposed upon the hardened substrate. The substrate is capable of being connected to electrical circuitry. Most preferably, the substrate is a metal screen that has been hardened, roughened and pitted by sandblasting before the catalytically active materials are disposed thereupon, and before the substrate is incorporated into an electrochemical metal air cell.
Inventors
- 👤 Robert B. Dopp
- 👤 John E. Oltman
- 👤 Joseph L. Passaniti
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 04:34
CPC Classifications
H; H01; H01M; H01M4/00; H01M4/02; H01M4/64; H01M4/66; H01M4/669; H01M12/00; H01M12/04; H01M12/06; H01M4/661; H01M4/70; H01M4/72; H01M4/74; H01M4/86; H01M2004/8678; H01M2004/8689; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y02P; Y02P70/00; Y02P70/50; Y10; Y10S; Y10S428/00; Y10S428/922; Y10S428/9265; Y10S428/929; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49108
Claims Analysis
Total Claims: 49
Claim 1
Independent Claim
46 words
An air cathode, comprising: (a) a current collecting substrate comprising a metal structure wherein the mean number of grain boundaries per 0.001 inch exceeds about 1.9 grain boundaries; and (b) an active layer comprising a matrix of catalytically active carbon surrounding elements of said metal structure.
Claim 2
Dependent Claim
46 words
An air cathode, comprising: (a) a current collecting substrate comprising a metal structure wherein the mean number of grain boundaries per 0.001 inch exceeds about 1.9 grain boundaries; and (b) an active layer comprising a matrix of catalytically active carbon surrounding elements of said metal structure.
Claim 3
Dependent Claim
25 words
An air cathode of claim 1 wherein the mean number of grain boundaries per 0.001 inch in said metal structure exceeds about 1.95 grain boundaries.
Claim 4
Dependent Claim
25 words
An air cathode of claim 1 wherein the mean number of grain boundaries per 0.001 inch in said metal structure exceeds about 1.97 grain boundaries.
Claim 5
Dependent Claim
25 words
An air cathode of claim 1 wherein the mean number of grain boundaries per 0.001 inch in said metal structure exceeds about 2.0 grain boundaries.
Claim 6
Dependent Claim
25 words
An air cathode of claim 1 wherein the mean number of grain boundaries per 0.001 inch in said metal structure exceeds about 2.3 grain boundaries.
Claim 7
Dependent Claim
38 words
An air cathode of claim 1 wherein said current collecting substrate comprises metal selected from the group consisting of nickel, Nickel alloy, silver, cobalt, titanium, copper, gold, palladium, platinum, steel, stainless steel, and plating-substrate combinations and alloys thereof.
Claim 8
Dependent Claim
64 words
An air cathode of claim 1 wherein said metal structure is selected from the group consisting of a metal screen, a planar metal member having at least one hole suitable for air ingress disposed therethrough, a woven nickel cross bonded screen, an expanded nickel screen, a support structure comprising a plurality of wires, and a planar support structure comprising a plurality of interconnected members.
Claim 9
Dependent Claim
27 words
An air cathode of claim 1 wherein said metal structure is a metal screen comprising wire having a diameter between about 0.002 inch and about 0.015 inch.
Claim 10
Dependent Claim
34 words
An air cathode of claim 1, said current collecting substrate and said active layer being disposed between an air diffusion layer and a barrier layer, said active layer being impregnated with an alkaline electrolyte.
Claim 11
Dependent Claim
26 words
An air cathode of claim 1 wherein said barrier layer comprises a porous barrier layer and said air diffusion layer comprises an hydrophobic air diffusion layer.
Claim 12
Dependent Claim
68 words
A current collecting substrate comprising wire having a diameter between about 0.002 inch and about 0.004 inch, and wherein the mean number of grain boundaries per 0.001 inch exceeds about 1.9 grain boundaries, said current collecting substrate having an overall diameter suitable for being received in and thereby being electrically connected to, a cathode can of an electrochemical cell having an overall outer diameter greater than 0.307 inch.
Claim 13
Dependent Claim
68 words
A current collecting substrate comprising wire having a diameter between about 0.002 inch and about 0.004 inch, and wherein the mean number of grain boundaries per 0.001 inch exceeds about 1.9 grain boundaries, said current collecting substrate having an overall diameter suitable for being received in and thereby being electrically connected to, a cathode can of an electrochemical cell having an overall outer diameter greater than 0.307 inch.
Claim 14
Dependent Claim
38 words
A current collecting substrate as in claim 11 wherein said substrate comprises metal selected from the group consisting of nickel, nickel alloy, silver, cobalt, titanium, copper, gold, palladium, platinum, steel, stainless steel, and plating-substrate combinations and alloys thereof.
Claim 15
Dependent Claim
38 words
A current collecting substrate as in claim 11 wherein said metal screen is selected from the group consisting of a woven nickel cross bonded screen, an expanded nickel screen, and a support structure comprising a plurality of wires.
Claim 16
Dependent Claim
29 words
An air cathode comprising a current collecting substrate of claim 11, and an active layer, comprising a matrix of catalytically active carbon, surrounding elements of said current collecting substrate.
Claim 17
Dependent Claim
21 words
A current collecting substrate as in claim 11, said wire having a diameter of about 0.002 inch to about 0.004 inch.
Claim 18
Dependent Claim
21 words
A current collecting substrate as in claim 11, said wire having a diameter of about 0.002 inch to about 0.003 inch.
Claim 19
Dependent Claim
39 words
A current collecting substrate as in claim 11, said current collecting substrate comprising metal selected from the group consisting of nickel, nickel alloy, silver, cobalt, titanium, copper, gold, palladium, platinum, steel, stainless steel, and plating-substrate combinations and alloys thereof.
Claim 20
Dependent Claim
70 words
A current collecting substrate as in claim 11, said wire being comprised in a structure comprising metal selected from the group consisting of a metal screen, a planar metal member having at least one hole suitable for air ingress disposed therethrough, a woven nickel cross bonded screen, an expanded nickel screen, a support structure comprising a plurality of wires, and a planar support structure comprising a plurality of interconnected members.
Claim 21
Dependent Claim
64 words
A metal-air electrochemical cell, comprising: (a) an anode; (b) a cathode, including a cathode can; (c) a separator between said anode and said cathode; and (d) a cathode assembly, in said cathode can, said cathode assembly comprising a current collecting substrate, said current collecting substrate comprising a metal structure wherein the mean number of grain boundaries per 0.001 inch exceeds about 1.9 grain boundaries.
Claim 22
Dependent Claim
64 words
A metal-air electrochemical cell, comprising: (a) an anode; (b) a cathode, including a cathode can; (c) a separator between said anode and said cathode; and (d) a cathode assembly, in said cathode can, said cathode assembly comprising a current collecting substrate, said current collecting substrate comprising a metal structure wherein the mean number of grain boundaries per 0.001 inch exceeds about 1.9 grain boundaries.
Claim 23
Dependent Claim
36 words
A metal-air electrochemical cell of claim 19, said cathode assembly including an active layer comprising a matrix of catalytically active carbon surrounding elements of said metal structure, said active layer being impregnated with an alkaline electrolyte.
Claim 24
Dependent Claim
26 words
A metal-air electrochemical cell of claim 19 wherein the mean number of grain boundaries per 0.001 inch in said metal structure exceeds about 1.95 grain boundaries.
Claim 25
Dependent Claim
26 words
A metal-air electrochemical cell of claim 19 wherein the mean number of grain boundaries per 0.001 inch in said metal structure exceeds about 2.0 grain boundaries.
Claim 26
Dependent Claim
26 words
A metal-air electrochemical cell of claim 19 wherein the mean number of grain boundaries per 0.001 inch in said metal structure exceeds about 2.3 grain boundaries.
Claim 27
Dependent Claim
28 words
A metal-air electrochemical cell as in claim 19, said anode comprising an anode can, and electrochemically active material in said anode can, said electrochemically active material comprising zinc.
Claim 28
Dependent Claim
39 words
A metal-air electrochemical cell as in claim 19, said current collecting substrate comprising metal selected from the group consisting of nickel, NICKEL 200, silver, cobalt, titanium, copper, gold, palladium, platinum, steel, stainless steel, and plating-substrate combinations and alloys thereof.
Claim 29
Dependent Claim
66 words
A metal-air electrochemical cell as in claim 19, said metal structure comprising metal selected from the group consisting of a metal screen, a planar metal member having at least one hole suitable for air ingress disposed therethrough, a woven nickel cross bonded screen, an expanded nickel screen, a support structure comprising a plurality of wires, and a planar support structure comprising a plurality of interconnected members.
Claim 30
Dependent Claim
73 words
A metal-air electrochemical cell, comprising: (a) an anode; (b) a cathode, including a cathode can; (c) a separator between said anode and said cathode; and (d) a cathode assembly, in said cathode can, said cathode assembly comprising a current collecting substrate, said current collecting substrate comprising metal wire having a diameter of about 0.002 inch to about 0.003 inch, said metal-air electrochemical cell having an overall outer diameter of greater than 0.307 inch.
Claim 31
Dependent Claim
73 words
A metal-air electrochemical cell, comprising: (a) an anode; (b) a cathode, including a cathode can; (c) a separator between said anode and said cathode; and (d) a cathode assembly, in said cathode can, said cathode assembly comprising a current collecting substrate, said current collecting substrate comprising metal wire having a diameter of about 0.002 inch to about 0.003 inch, said metal-air electrochemical cell having an overall outer diameter of greater than 0.307 inch.
Claim 32
Dependent Claim
39 words
A metal-air electrochemical cell as in claim 22, said current collecting substrate comprising metal selected from the group consisting of nickel, nickel alloy, silver, cobalt, titanium, copper, gold, palladium, platinum, steel, stainless steel, and plating-substrate combinations and alloys thereof.
Claim 33
Dependent Claim
70 words
A metal-air electrochemical cell as in claim 22, said wire being comprised in a structure comprising metal selected from the group consisting of a metal screen, a planar metal member having at least one hole suitable for air ingress disposed therethrough, a woven nickel cross bonded screen, an expanded nickel screen, a support structure comprising a plurality of wires, and a planar support structure comprising a plurality of interconnected members.
Claim 34
Dependent Claim
22 words
A metal-air electrochemical cell as in claim 22 wherein the mean number of grain boundaries per 0.001 inch exceeds 1.9 grain boundaries.
Claim 35
Dependent Claim
21 words
A metal-air electrochemical cell as in claim 27 wherein the mean number of grain boundaries per 0.001 inch exceeds 2.0 boundaries.
Claim 36
Dependent Claim
21 words
A metal-air electrochemical cell as in claim 27 wherein the mean number of grain boundaries per 0.001 inch exceeds 2.3 boundaries.
Claim 37
Dependent Claim
24 words
An air cathode as in claim 1 wherein said metal structure comprises wire having a diameter between about 0.002 inch and about 0.005 inch.
Claim 38
Dependent Claim
24 words
An air cathode as in claim 1 wherein said metal structure comprises wire having a diameter between about 0.002 inch and about 0.004 inch.
Claim 39
Dependent Claim
24 words
An air cathode as in claim 1, wherein said metal structure comprises wire having a diameter between about 0.002 inch and about 0.003 inch.
Claim 40
Dependent Claim
18 words
A current collecting substrate comprising metal wire having a diameter between about 0.002 inch and about 0.003 inch.
Claim 41
Dependent Claim
18 words
A current collecting substrate comprising metal wire having a diameter between about 0.002 inch and about 0.003 inch.
Claim 42
Dependent Claim
22 words
A current collecting substrate as in claim 36 wherein the mean number of grain boundaries per 0.001 inch exceeds 1.9 grain boundaries.
Claim 43
Dependent Claim
22 words
A current collecting substrate as in claim 36 wherein the mean number of grain boundaries per 0.001 inch exceeds 2.0 grain boundaries.
Claim 44
Dependent Claim
22 words
A current collecting substrate as in claim 36 wherein the mean number of grain boundaries per 0.001 inch exceeds 2.3 grain boundaries.
Claim 45
Dependent Claim
41 words
A cathode assembly, comprising: (a) a current collecting substrate comprising metal wire having a diameter between about 0.002 inch and about 0.003 inch; and (b) an active layer comprising a matrix of catalytically active carbon surrounding elements of said metal wire.
Claim 46
Dependent Claim
41 words
A cathode assembly, comprising: (a) a current collecting substrate comprising metal wire having a diameter between about 0.002 inch and about 0.003 inch; and (b) an active layer comprising a matrix of catalytically active carbon surrounding elements of said metal wire.
Claim 47
Dependent Claim
25 words
A cathode assembly as in claim 40 wherein the mean number of grain boundaries in said metal wire per 0.001 inch exceeds 1.9 grain boundaries.
Claim 48
Dependent Claim
25 words
A cathode assembly as in claim 40 wherein the mean number of grain boundaries in said metal wire per 0.001 inch exceeds 2.0 grain boundaries.
Claim 49
Dependent Claim
25 words
A cathode assembly as in claim 40 wherein the mean number of grain boundaries in said metal wire per 0.001 inch exceeds 2.3 grain boundaries.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2000-08-11 | 2001-02-10 | 2001-08-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-08-11 | 2005-02-10 | 2005-08-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-08-11 | 2009-02-10 | 2009-08-12 | $7700.00 | Window Closed / Lapsed |