Patent ID: 7351495

Claim:
A method of adding electrolyte solution to an alkaline cell comprising a casing having an open end and opposing closed end and at least one flat surface along its length, comprising: (a) inserting cathode material comprising manganese dioxide into the casing so that a cathode surface faces the casing and an opposing exposed cathode surface faces the cell interior; (b) inserting a separator into the casing so that a surface of the separator faces said exposed surface of said cathode, wherein said separator is of non-electrically conductive material permeable to alkaline electrolyte, wherein said separator has a bag shape and comprises a body surface having an open end and opposing closed end, wherein said body surface defines a cavity for insertion of anode material therein, wherein said separator body surface defining said cavity has an oblong configuration when viewed in cross section along a plane taken perpendicular to the cell's central longitudinal axis there being a gap between at least a portion of said separator and the cathode, wherein said gap between said separator and said cathode is between about 2 and 4 mm wide and runs along the length of said separator; (c) inserting anode slurry material comprising zinc particles into the cavity defined by the body surface of said separator so that the separator is between said anode and cathode; (d) adding alkaline electrolyte solution comprising aqueous potassium hydroxide directly to said gap, wherein at least a portion of said added electrolyte is absorbed into the anode thereby causing the anode to expand and close said gap between separator and cathode.