Abstract: A battery powered device providing in combination (1) a cell pack that includes one or more isolation passageways (diffusion tubes) positioned to protect metal-air cells of the battery pack from the ambient air when no air mover is active to force air to the cells and the passageway or passageways remain unsealed, and (2) an electrical device configured to removably receive the cell pack in a manner which allows an air mover associated with the electrical device to communicate with at least one of the isolation passageways of the cell pack to provide air to air electrodes of the cells.

Abstract: Air managers for metal-air batteries are described, utilizing a diaphragm or bellows to move air in and out of one or more air openings or to move air from an inlet to an outlet. The diaphragm or bellows may be reciprocated by a linear actuator, such as an electromagnetic oscillator, or a shape memory alloy wire. Micromachines such as microrelays may be used as actuators. The battery may include one or more air passageways preferably including an isolating passageway such as a thin elongate tube shaped to impede air flow to the air electrode when the air moving device is not operative, even while the tube remains unsealed. The result is an improved air moving device for metal-air cells that occupies a minimal amount of the volume available for battery chemistry, is usable with advanced systems for isolating the air electrodes when power is not being drawn from the metal air cell, and is capable of developing high pressure for high velocity air movement at a relatively low rate of power consumption.

Abstract: A device for damping vibration in mounting vibration-prone devices, such as fans or other devices with moving parts. A fan may be mounted at the center of a spiral spring to prevent transmission of vibrations including sounds from the fan to a surrounding structure, such as a cell phone powered by a metal-air battery.

Abstract: A metal-air cell housing structure provides a generally L-shaped peripheral grid comprising an upper leg ultrasonically welded to the top edge of a peripheral wall of a lower housing section, and a downwardly extending leg positioned to hold an air electrode against the central panel of the lower housing section. An upper housing section encloses the lower housing section with a top panel and an outer peripheral wall that extends downwardly adjacent to and is adhered to the peripheral grid and the lower housing peripheral wall.

Abstract: A manganese based catalyst for use in a metal-air electrochemical cell wherein the catalyst is made by a sol-gel process. The sol-gel process creates catalyst particles that are submicron and easily distributed throughout the active layer of the electrode.

Abstract: The metal-air battery includes an air mover mechanism located in the cathode plenum space of one or more metal-air cells. The air mover is an enclosure isolating the air cathode, with a mechanism for expanding and contracting the volume of the enclosure to move air in and out of the enclosure. Prismatic and cylindrical batteries incorporating the invention are described.

Abstract: A manganese based catalyst for use in a metal-air electrochemical cell wherein the catalyst is made by a micelle process and a method of producing the catalyst. An electrode comprising said catalyst and method of producing the electrode. The micelle encapsulation process creates catalyst particles that are submicron and easily distributed throughout the active layer of the electrode.

Abstract: An orientation independent metal-air power source utilizing convective airflow for enhancing power output for powering a load. A battery housing for enclosing at least one metal-air cell has an air cavity at each end. Between the two cavities is an elongated central passageway. The cavities are preferably disk-shaped and include a circular resistance element in their outer periphery. A central gravity switch with a conductive ball and a plurality of contact pairs is coupled to the resistance elements. Each of the contact pairs is associated with a particular angular orientation of the metal-air battery. At least a portion of one of the resistance elements is heated when the ball comes into contact with one of the contact pairs. A plurality of isolating passageways pass sufficient airflow to the oxygen electrode, while the resistance element portion is heated, and restricts airflow to the oxygen electrode when the resistance element portion is not heated.

Abstract: A metal-air cell having a cell casing, an air electrode positioned within the cell casing, and means for providing air to the air electrode when a predetermined load is placed on the cell and for substantially isolating the air electrode when the load is not placed on the cell.

Abstract: A ventilation system for a metal-air battery is disclosed. The metal-air battery has one or more air cathodes, one or more air pathways from the air cathode to a reactive gas source, a closure member associated with each of the air pathways to selectively prevent the flow of gas through the air pathways and one or more volume-changeable plenums in fluid communication with the air pathway and the air cathode. When the battery is not in use, the closure member is closed and the door is closed to save the battery life time. When the battery is activated, the air pathway is opened and the volume of the plenum is increased to introduce fresh air from the outside to the plenum. A method of producing electricity using a metal-air battery is also disclosed.

Abstract: A ventilation system for metal-air battery cells having collapsible isolation passageways for controlling ambient airflow to the oxygen electrode of the metal-air battery. The ventilation system has at least one inlet isolation passageway and at least one outlet isolation passageway. The isolation passageways normally remain in a collapsed position to restrict airflow when an air mover is turned off. The isolation passageways may be configured into an expanded position in response to airflow generated by the air mover. In the expanded position, the inlet isolation passageway permits ambient air to flow across the oxygen electrode and the outlet isolation passageway permits oxygen depleted air to be expelled.

Abstract: A metal-air battery with an air moving device controller to determine when a load is present on the battery and the extent of that load is described. The air moving device controller allows the operation of the air moving device for the battery to be responsive to the load. Advantageously, the controller allows the metal-air battery to limit the intake of oxygen and other gases to that amount needed to drive the load.

Abstract: A bifunctional air electrode for a rechargeable metal-air cell is made with water soluble oxygen reduction and oxygen evolution catalyst precursors. The resulting air electrode exhibits greater power output than a conventional air electrode.

Abstract: A cylindrical metal-air cell has a cylindrical housing, an axially extending cylindrical air cathode adjacent an interior surface of the housing, and a plurality of elongate plenums defined between the oxygen electrode and the interior surface of the housing. Isolating passageway are positioned between the ambient environment and each of the plenums, and an air moving device is operable to force air through the isolating passageways and into at least one of the plenums. The air moving device may be a micromachined blower controlled by a circuit integrated into the housing of the blower.

Abstract: A metal-air cell with an anode container. The anode container is made from a reactive metal. The metal-air cell also has an absorbent layer with a first side and a second side. An electrolyte is substantially trapped within the absorbent layer. The first side of the absorbent layer is positioned in contact with the anode container and an air electrode is positioned in contact with the second side of the absorbent layer.

Abstract: A primary metal-air power source containing one or more metal-air cells incorporating an air manager in a power source housing of the power source. The power source provides intermittent use at high power levels over a long lifetime while demonstrating a high utilization of the metal, such as zinc, making up the metal-air cell's metal anode. The power source provides 80% of its amp hour capacity for at least 30 days after the initial partial discharge at a power level of at least 50 milliwatts. The cumulative run time may comprise any number of intermittent connections to a load having varying duration. The ventilation system of the power source draws ambient airflow through an isolating passageway by operating an air mover which distributes the airflow to the metal-air cells.

Abstract: A cylindrical metal-air cell has a cylindrical housing, an axially extending cylindrical air cathode adjacent an interior surface of the housing, and a plurality of elongate plenums defined between the oxygen electrode and the interior surface of the housing. Isolating passageway are positioned between the ambient environment and each of the plenums, and an air moving device is operable to force air through the isolating passageways and into at least one of the plenums. The air moving device may be a micromachined blower controlled by a circuit integrated into the housing of the blower.

Abstract: An improved metal-air battery having a metal-air cell stack positioned within a substantially uniform shell. The metal-air cell stack includes an isolating passageway and a substantially oxygen-permeable, water impermeable shell.

Abstract: An anode for use in an electrochemical cell comprises a plate of non-particulate, mercury-free zinc metal and a coating of indium metal on at least a portion of the zinc plate surface. The anode is particularly useful in a rechargeable metal-air cell. The elimination of mercury enhances the safety of the cell and the indium coating reduces gassing at the anode and corrosion of the anode. Desirably, the electrolyte in the metal air cell also includes indium hydroxide. Also, a method for making the anode using a hot-plate joining process.

Abstract: An air-managing system for metal-air battery includes resealable septum and one or more hollow needles. The septum separates air pathway into two segments. One segment is from air cathodes of the battery to the septum and the other is from the septum to the outside air. The needles provide conduits to connect two segments. The septum re-closes its torn portion when the needles are removed. Also disclosed is a reusable air manager including a fan and such needles. The air manager can be coupled to a disposable cell pack which has a septum that can be pierced by the needles.