METHOD FOR MANUFACTURING A LITHIUM-IRON DISULFIDE CELL

The invention relates to a method for making a cathode outer wrap battery, the method comprising:providing a continuous coating of a cathode mixture comprising iron disulfide onto both sides of a solid foil current collector to form a coated cathode and subsequently creating a plurality of zones of reduced electrochemical activity on at least one side of the current collector;cutting the coated cathode into a plurality of individual cathode strips so that a zone of reduced electrochemical activity is positioned at a terminal end of each of the plurality of individual cathode strips;providing a separator and an anode consisting essentially of lithium or a lithium alloy wherein the anode does not include a current collector;spirally winding the anode, an individual cathode strip of the plurality of individual cathode strips and the separator into an electrode assembly so that at least 50% of an outermost surface of the electrode assembly, excluding the separator and optional non-active components, is covered by the individual cathode strip and the zone of reduced electrochemical activity is situated along the outermost surface of the electrode assembly; anddisposing the electrode assembly in a conductive container, introducing a nonaqueous electrolyte to the conductive container and closing the conductive container to form an electrochemical cell.