Rayovac Corporation

Sarnoff Corporation

Other

Etymotic Research, Inc.

Esb Incorporated

John Edward Oltman

Robert B Dopp

Joseph Lynn Passaniti

John David Burns

Gregory Scott Moy

Michael Andrew Ward

Robert Adey

Michael J Root

Walter Paul Sjursen

Marvin Allan Leedom

John Gregory Aceti

Robert Richard Demers

Derek Dwayne Mahoney

John Michael Margicin

Frederick J Fritz

Robert C Maxwell

Patrick J Spellman

Michael H Tardugno

Randall L Collien

Denis D Carpenter

Mead C Killion

Stephen Drake Julstrom

Timothy Scott Monroe

Ralph H Feldhake

Robert B Loch

John Claude Springstead

Gerald F Sanden

Susan Jean Launder

Rechargeable battery assemblies and methods of constructing rechargeable battery assemblies are provided. Rechargeable battery assemblies can include a storage cell and receive circuitry comprising a receive coil operatively connected to receive control circuitry, the receive coil configured to receive inductively coupled current, the receive control circuitry configured to rectify the current and communicate charging power to the storage cell, the coil wound around a shield/core comprising magnetically permeable material, and the shield/core disposed around the storage cell. Methods of constructing rechargeable battery assemblies can include disposing a shield/core comprising magnetically permeable material around a storage cell; winding a receive coil around the shield/core; and providing the receive coil in operative connection with receive control circuitry and the storage cell, the receive coil configured to receive inductively coupled current, and the receive control circuitry configured to rectify the current and communicate charging power to the storage cell.

Rechargeable battery assemblies and methods of constructing rechargeable battery assemblies

A hearing aid is enclosed in a gas-impermeable or substantially gas-impermeable package to prevent inadvertent activation of the hearing aid during transport. The package may include a housing having a groove that substantially conforms to at least a portion of the shape of the hearing aid to snugly hold the hearing aid. The groove may be substantially open adjacent a switch on the hearing aid. A securing member, such as a strap, may be used to immobilize the switch relative to the housing.

Hearing aid package

A disposable hearing aid insertable into an ear canal which includes a microphone which translates acoustic energy into electrical signals, signal processing circuitry which processes the electrical signals provided by the microphone, a receiver which converts the processed electrical signals into acoustic energy, and a power source permanently disposed within the hearing aid such that the source is substantially non-removeably integrated with the hearing aid.

Hearing aid

A hearing aid insertable into an ear canal includes a microphone which translates acoustic energy into electrical signals, signal processing circuitry which processes the electrical signals provided by the microphone, a receiver which converts the processed electrical signals into acoustic energy, and a power source connectable to the signal processing circuitry.

Cathode cans for use in air depolarized cells, and cells made with such cans. The side wall is stronger than the bottom wall, and has a smoother outwardly-disposed surface than the respective bottom wall surface. Strength, and thus hardness, of the side wall relates to strength, and thus hardness, of the bottom wall, as hardness of 130-185 relates, to hardness of 93-117, on the Vickers scale. Preferred hardness of the side wall is about 130 to 185; and of the bottom wall is about 93 to 117. The side wall is drawn, and an outwardly-disposed surface of the side wall is ironed. As ironed, the surface finish is related to surface finish of the bottom wall, at the same stage, as surface finish R of less than 2, preferably about 0.5 to about 1.5, microinches, is related to surface finish R of about 2 to about 5, preferably about 2.5 to about 4.5, microinches. Thickness of the side wall is generally up to about 85 percent as great as thickness of the bottom wall. In methods of forming cathode cans in a metal strip, a die has an initializing land, an inner side wall, a cavity inwardly of the inner side wall, and a lip between the initializing land and the inner side wall.

Air depolarized electrochemical button cell

An elongate, generally tubular, air depolarized electrochemical cell ( ) comprising a cathode ( ), including an air cathode assembly ( ), extending about the tubular circumference, and along the tubular length, of the cell ( ), an anode ( ), a separator ( ) between the anode ( ) and the cathode ( ), electrolyte, a top closure member ( ), and a bottom closure member ( ). The cathode assembly ( ) is fixedly held, by a friction fit, in a slot ( ) at the bottom of the cell. The slot can be developed, for example, by inner ( ) and outer ( ) walls of a cathode can ( ), by inner ( ) and outer ( ) walls of a bottom closure member ( ), or by an outer wall ( ) of a cathode can ( ) and an opposing outer wall of a plug ( ) on the interior of the cell. Preferably, bottom closure structure of the cell ( ) and receives a bottom edge portion ( ) of the cathode current collector ( ), and makes electrical contact with the bottom edge portion ( ), preferably at an inner surface ( ) of the cathode current collector. A diffusion member ( ) of the cathode assembly ( ) is preferably compressed as a seal, at the bottom of the cell ( ), between an outer side wall ( ) of the cell and the remainder of the cathode assembly ( ). The diffusion member ( ) is also used at least as an assist in sealing the cell ( ) against electrolyte leakage from the anode cavity ( ) and past the cathode assembly ( ). An embodiment may provide a stop ledge ( ) in grommet ( ) facing a stop groove ( ) in a cathode can ( ). The cathode assembly ( ) can extend into a slot ( ) at an outer edge of the grommet ( ). A top grommet ( ) can have an upwardly extending leg ( A) overlain by a top closure member ( ). The air diffusion member ( ) may control the rate of entry of air to the reaction surface, depending on density of the air diffusion member ( ), whereby the air diffusion member ( ) controls the limiting current of the cell ( ). The air cell ( ) can be free from adhesive bonding the separator ( ) to the cathode assembly ( ). The bottom of the cathode current collector ( ) may be in a bottom slot ( ), in a path of flow of current between a reaction surface and a positive electrode terminal ( ). A method of fabricating cells can including crimping a top washer ( ) and an outer leg ( ) of a top grommet ( ) at the same time, including closing a slot ).

Air depolarized electrochemical cells

An elongate, generally tubular, air depolarized electrochemical cell ( ) comprising a cathode ( ), including an air cathode assembly ( ), extending about the tubular circumference, and along the tubular length, of the cell ( ), an anode ( ), a separator ( ) between the anode ( ) and the cathode ( ), electrolyte, a top closure member ( ), and a bottom closure member ( ). The cathode assembly ( ) is fixedly held, by a friction fit, in a slot ( ) at the bottom of the cell. The slot can be developed, for example, by inner ( ) and outer ( ) wars of a cathode can ( ), by inner ( ) and outer ( ) walls of a bottom closure member ( ), or by an outer wall ( ) of a cathode can ( ) and an opposing outer wall of a plug ( ) on the interior of the cell. Preferably, bottom closure structure of the cell ( ) and receives a bottom edge portion ( ) of the cathode current collector ( ), and makes electrical contact with, the bottom edge portion ( ), preferably at an inner surface ( ) of the cathode current collector. A diffusion member ( ) of the cathode assembly ( ) is preferably compressed as a seal, at the bottom of the cell ( ), between an outer side wall ( ) of the cell and the remainder of the cathode assembly ( ). The diffusion member ( ) is also used at least as an assist in sealing the cell ( ) against electrolyte leakage from the anode cavity ( ) and past the cathode assembly ( ). Various embodiments comprehend a variety of bottom seal members ( ) between the bottom wall ( ) and the electroactive anode material ( ), typically in combination with a bottom slot ( ) receiving the cathode assembly ( ) adjacent an outer side wall ( ) of the bottom closure member ( ).

Bottom seals in air depolarized electrochemical cells

Cathode assembly precursor cathode assembly (,) and elongate air depolarized electrochemical cells (,) made therewith. Cathode assembly precursor comprises a closed-loop elongate cathode current collector (,), and perforations (,) from outer to inner surfaces, and catalystically active carbon extending into the perforations (,). The current collector (,) can be cylindrical and can be free from longitudinal jointing, or can have a longitudinal joint (,), preferably free from overlap of the side wall. The current collector (,) can comprise an imperforate edge region at the top (,) and/or bottom (,), left (,) and/or right (,) edge. The perforations (,) define an open traction of the wall, of about 45 to about 70 percent. Typical cathode assemblies (,) have air diffusion member (,) on the outer surface of the cathode assembly (,). Such air diffusion member (,) typically has thickness of about 0.0025 to 0.005 inch (about 0.06 to about 0.13 mm.), and comprises a reduced thickness endless wrap extending at least 1.5 times, preferably 2 times, or 3 times, about the current collector (,), discouraging transfer of moisture vapor into or out of a cell, discouraging leakage, and controlling air diffusion rate. The diffusion member (,) extends beyond the top edge (,) of the current collector, and is folded in and down about the top edge (,) and inner surface (,) of the cathode assembly (,). The cathode current collector (,) can be mounted on a mandrel (,), the carbon sheet (,) passing through a nip defined between (i) support structure (,) having greater arc radius than the mandrel (,) and (ii) the mandrel (,), and applying force at the nip to consolidate the carbon (,) onto the side wall (,), passing air diffusion material (,) through the nip, and applying force to consolidate the air diffusion material (,) onto the carbon (,). The invention contemplates fabricating an air cathode assembly (,) comprising mounting the current collector (,) on a mandrel (,), defining an arc having a radius smaller than the arc of the cathode current collector (,), mounting the combination mandrel (,) and cathode current collector (,) in a stack (,) of assembly rolls (,A,,B,,C,,D), making a sheet stack of carbon sheets (,B,,C,,D), passing the sheet stack through a nip, and applying force to the stack, reducing thickness of the stack, and passing air diffusion material (,) through the nips and applying force to consolidate the diffusion material (,) onto the carbon (,).

Composite carbon sheet, and electrochemical cells made therewith

This invention pertains to metal-air electrochemical cells wherein one or more air entry ports is located in the bottom of the cathode can, to provide for entry of oxygen-rich air into the cathode can, where the oxygen participates in the electrochemical reaction whereby the cell produces electrical energy. In this invention, extremely small air ports are provided, along with methods of reliably fabricating such small air ports, where a tool impression extends around the port. Generally, the use of an increased number of small air ports distributed over the bottom of the cathode can, opposite the reaction surface of the cathode assembly, wherein the overall open area of the ports is not increased, results in less moisture traversing the air ports, into or out of the cell. Accordingly, moisture loss, or gain, as a function of electrical energy produced, is thereby reduced.

Metal-air cathode can, and electrochemical cell made therewith

This invention pertains to metal-air electrochemical cells wherein one or more air entry ports is located in the bottom of the cathode can, to provide for entry of oxygen-rich air into the cathode can, where the oxygen partcicpates in the chemical reaction whereby the cell produces electrical energy. In this invention, multiple small air entry ports are provided. Generally, the use of multiple ports distributed over the bottom of the cathode can, opposite the reaction surface of the cathode assembly, while not increasing the overall open area of the ports, results in an increase in the ratio of the cell limiting current to the rate at which moisture is lost from the cell. Accordingly, moisture loss as a function of electrical energy produced, is less.

Metal-air cathode can and electrochemical cell made therewith

This invention pertains to electrochemical cells, typically to air depolarized cells of the button-type. Non-reactive elements of cells of the invention are thinner than corresponding non-reactive elements of prior art cells. Such elements can be made thinner because of improved structures of such elements. The anode can is made from a metal strip structure having a higher steel content. The cathode can preferably has improved stiffness and rigidity while retaining sufficient ductility to tolerate forming the cathode can. By so reducing the thicknesses of non-reactive elements of the cell, and thus the volume occupied by such non-reactive elements, the fraction of the cell devoted to holding electrochemically reactive anode material therein is increased, with corresponding increase in the milliampere hour capacity of the cell.

Electrochemical cells and components thereof

An elongate, generally tubular, air depolarized electrochemical cell (,) comprising a cathode (,), including an air cathode assembly (,), extending about the tubular circumference, and along the tubular length, of the cell (,), an anode (,), a separator (,) between the anode (,) and the cathode (,), electrolyte, a top closure member (,), and a bottom closure member (,). The cathode assembly (,) is fixedly held, by a friction fit, in a slot (,) at the bottom of the cell. The slot can be developed, for example, by inner (,) and outer (,) walls of a cathode can (,), by inner (,) and outer (,) walls of a bottom closure member (,), or by an outer wall (,) of a cathode can (,) and an opposing outer wall of a plug (,) on the interior of the cell. Preferably, bottom closure structure of the cell (,) and receives a bottom edge portion (,) of the cathode current collector (,), and makes electrical contact with the bottom edge portion (,), preferably at an inner surface (,) of the cathode current collector. A diffusion member (,) of the cathode assembly (,) is preferably compressed as a seal, at the bottom of the cell (,), between an outer side wall (,) of the cell and the remainder of the cathode assembly (,). The diffusion member (,) is also used at least as an assist in sealing the cell (,) against electrolyte leakage from the anode cavity (,) and past the cathode assembly (,). Various embodiments comprehend crimping bias in various members at the bottom of the cell (,), to develop the friction fit that fixedly holds the cathode assembly (,) at the bottom of the cell (,). In a can-less embodiment, top (,) and bottom (,) closure members can be separate and distinct from each other, and at least a portion of the air cathode assembly (,) is openly exposed as an outer surface to the ambient environment. A portion of the air diffusion member (,) is compressed in the bottom closure member as a seal.

Elongate air depolarized electrochemical cells

An elongate air depolarized electrochemical cell (,). A grommet (,) closes the top of the cell (,). A seal (,) can extend upwardly into a slot (,) between the grommet (,) and a top closure member (,) such as at the top of a cathode can (,), or a separate top closure member (,). Cathode assembly (,) and separator (,) can extend into the slot (,). The seal is between the grommet (,) and cathode assembly (,), or between grommet (,) and separator (,). or both. The seal can extend upwardly into the slot (,) from an outer surface of the cathode assembly (,), can extend about respective upper edges of the cathode current collector (,), catalyst, and separator (,), and downwardly toward, preferably against or along the inner surface of, the separator (,). The top closure member (,) can be crimped against the grommet (,) at the slot (,), with the cathode assembly (,), and optionally the separator (,), in the slot (,) between the grommet (,) and the top closure (,), thus to provide a liquid-tight crimp seal. The top closure (,) can be crimped first against the grommet (,) at the slot (,), and further crimped against the grommet (,) at a second locus (,) displaced longitudinally from the first crimp. Composition of the seal comprises a microporous polymer (,), preferably polytetrafluoroethylene. Preferred embodiments comprise at least two, preferably at least three, layers of air permeable microporous sheet material, useful for diffusion of air therethrough to the cathode reaction surface (,). The layers are wrapped continuously and without intervening end, to form an outer surface of the cathode assembly (,). Another expression of the invention is a cathode assembly (,), or cathode-separator combination, for use in an elongate air depolarized cell (,). The air permeable sheet material (,), as wrapped about the tubular cathode assembly, is compressed so as to have a compressed thickness less than the uncompressed thickness. The invention still further comprehends an elongate air depolarized cell (,) comprising an anode, a cathode, or cathode-separator combination as described herein, and electrolyte.

Seals, and electrochemical cells made therewith

Cathode cans for use in air depolarized cells, and cells made with such cans. The side wall is stronger than the bottom wall, and has a smoother outwardly-disposed surface than the respective bottom wall surface. Strength, and thus hardness, of the side wall relates to strength, and thus hardness, of the bottom wall, as hardness of 130-185 relates to hardness of 93-117, on the Vickers scale. Preferred hardness of the side wall is about 130 to 185; and of the bottom wall is about 93 to 117. The side wall is drawn, and an outwardly-disposed surface of the side wall is ironed. As ironed, the surface finish is related to surface finish of the bottom wall, at the same stage, as surface finish R,of less than 2, preferably about 0.5 to about 1.5, microinches, is related to surface finish R,of about 2 to about 5, preferably about 2.5 to about 4.5, microinches. Thickness of the side wall is generally up to about 85 percent as great as thickness of the bottom wall. In methods of forming cathode cans in a metal strip, a die has an initializing land, an inner side wall, a cavity inwardly of the inner side wall, and a lip between the initializing land and the inner side wall. Ratio of outer radius of the lip to inner radius of the lip is about 2/1 to about 8/1. Ratio of clearance between punch and die to thickness of the metal strip is about 0.5/1 to about 0.85/1, whereby moving the punch and metal strip into the cavity draws the metal, and irons the outer surface of the metal.

Method for making a cathode can from metal strip

An elongate, generally tubular, air depolarized electrochemical cell (,) comprising a cathode (,), including an air cathode assembly (,), extending about the tubular circumference, and along the tubular length, of the cell (,), an anode (,). a separator (,) between the anode (,) and the cathode (,), electrolyte, a top closure member (,), and a bottom closure member (,). The cathode assembly (,) is fixedly held, by a friction fit, in a slot (,) at the bottom of the cell. The slot can be developed, for example, by inner (,) and outer (,) walls of a cathode can (,), by inner (,) and outer (,) walls of a bottom closure member (,), or by an outer wall (,) of a cathode can (,) and an opposing outer wall of a plug (,) on the interior of the cell. Preferably, bottom closure structure of the cell (,) and receives a bottom edge portion (,) of the cathode current collector (,), and makes electrical contact with the bottom edge portion (,), preferably at an inner surface (,) of the cathode current collector. A diffusion member (,) of the cathode assembly (,) is preferably compressed as a seal, at the bottom of the cell (,), between an outer side wall (,) of the cell and the remainder of the cathode assembly (,). The diffusion member (,) is also used at least as an assist in sealing the cell (,) against electrolyte leakage from the anode cavity (,) and past the cathode assembly (,). The tubular cathode current collector (,) has novel border regions (,), novel longitudinal joint structure (,), novel perforations (,), and including novel methods of making such cathode current collectors (,) and such cells (,).

Growing community of inventors

Mount Horeb, WI, United States of America

John Edward Oltman