Cylindrical battery cell having improved power characteristics and methods of manufacturing same

Abstract

A battery cell, such as a cylindrical alkaline cell, is disclosed having significantly improved capacity utilization at high discharge rates while maintaining much of the energy content and other feature advantages of typical cylindrical alkaline cells, by implementing a novel cell construction that produces increased surface area between the anode and cathode. One particular characterization of the cell construction of the present invention comprises an electrochemical battery cell comprising a cell housing defining an interior space having an interior surface, a first terminal and a second terminal. The cell further comprises an inner electrode encapsulated by a separator and disposed within the interior space of the housing. The inner electrode has a thin cross section in a folded configuration and is formed such that an outer extent of the inner electrode is generally conforming to a contour defined by the interior surface of the cell housing. The inner electrode is in electrical communication with the second terminal of the housing. An outer electrode is disposed within the interior space of the housing such that it is in ionic communication with the inner electrode and in electrical communication with the first terminal of the cell housing.