Abstract: The present invention provides one with a battery having an iron anode, e.g., a Ni—Fe battery, having improved performance characteristics. The battery uses a particular electrolyte and/or battery separator. The resulting characteristics of efficiency, charge retention and cycle life are much improved over such batteries in the prior art.

Abstract: The present invention provides one with an iron electrode employing a binder comprised of polyvinyl alcohol (PVA) binder. In one embodiment, the invention comprises an iron based electrode comprising a single layer of a conductive substrate coated on at least one side with a coating comprising an iron active material and a binder, wherein the binder is PVA. This iron based electrode is useful in alkaline rechargeable batteries, particularly as a negative electrode in a Ni—Fe battery.

Abstract: Providing is a battery comprising an iron anode, a nickel cathode, and an electrolyte comprised of sodium hydroxide, lithium hydroxide and a soluble metal sulfide. In one embodiment the concentration of sodium hydroxide in the electrolyte ranges from 6.0 M to 7.5 M, the amount of lithium hydroxide present in the electrolyte ranges from 0.5 to 2.0 M, and the amount of metal sulfide present in the electrolyte ranges from 1-2% by weight.

Abstract: Provided is a Ni—Fe battery comprising a high quality, high performance iron electrode. In one embodiment the iron electrode comprises a polyvinyl alcohol binder. The iron electrode of the Ni—Fe battery comprises a single conductive substrate coated on one or both sides with an iron active material.

Abstract: Provided is a continuous process for preparing a high quality and high performance iron electrode. The process comprises preparing a formulation comprising an iron active material and a binder and coating a continuous substrate material on a least one side with the formulation. The coated continuous substrate material is dried, compacted and blanked. A tab is then attached to the electrode.

Abstract: Provided is a process for activating a battery comprising an iron electrode. The process comprises providing a battery comprising a cathode and an iron anode. The battery further comprises an electrolyte comprising NaOH, LiOH and a sulfide. The battery is then cycled to equalize the state-of-charge of the cathode and iron anode.

Abstract: Provided is a high quality and high performance iron electrode, which is prepared by a continuous process. The process comprises preparing a formulation comprising an iron active material and a binder, and coating a continuous substrate material on at least one side with the formulation. The coated continuous substrate material is dried, compacted and blanked. A tab is then attached to the electrode. In one embodiment, the iron electrode comprises a PVA binder.

Abstract: The present invention provides one with a high cycle life Ni—Fe battery. The battery uses a particular electrolyte. The resulting characteristics of cycle life, as well as power and charge retention, are much improved over conventional Ni—Fe batteries.

Abstract: Provided is a flat plate electrode cell, comprises positive electrode plates and negative electrode plates. The positive electrode plates each comprise manganese and compressed metal foam. The negative electrode plates each comprise zinc and compressed metal foam. Both the positive and negative electrodes can have alignment tabs, wherein the flat plate electrode cell can further comprise electrical terminals tanned from the aligned tabs. The rechargeable flat plate electrode cell of the present disclosure, formed from compressed metal foam, provides both low resistance and high rate performance to the electrodes and the cell. Examples of improvements over round bobbin and flat plate cells are current density, memory effect, shelf life, charge retention, and voltage level of discharge curve. In particular, the rechargeable flat plate electrode cell of the present disclosure provides longer cycle life with reduced capacity fade as compared with known round bobbin and flat plate cells.

Abstract: Provided is a flat plate electrode cell, comprises positive electrode plates and negative electrode plates. The positive electrode plates each comprise manganese and compressed metal foam. The negative electrode plates each comprise zinc and compressed metal foam. Both the positive and negative electrodes can have alignment tabs, wherein the flat plate electrode cell can further comprise electrical terminals tanned from the aligned tabs. The rechargeable flat plate electrode cell of the present disclosure, formed from compressed metal foam, provides both low resistance and high rate performance to the electrodes and the cell. Examples of improvements over round bobbin and flat plate cells are current density, memory effect, shelf life, charge retention, and voltage level of discharge curve. In particular, the rechargeable flat plate electrode cell of the present disclosure provides longer cycle life with reduced capacity fade as compared with known round bobbin and flat plate cells.

Abstract: Battery management may be provided. First, a battery string in a battery bank may be charged for a charge time. After charging the battery string, the battery string may be isolated from charging for a rest time. Once the charging and resting from charging is complete, a test open circuit voltage for each battery in the first battery string may be measured. In addition, a defective indicator that a battery is defective may be recorded in a database. Next, a battery may be loaded with a preset load for a load time. After loading the battery, a test load voltage for each of the batteries loaded with the preset load may be measured. A second defective indicator that a battery is defective may be recorded in the database when the test load voltage for the second battery is greater than a load voltage differential.

Abstract: System and methods of supplying power to a load are provided. A module monitors electrical grid power. When the grid power fails the module initially provides power from a performance battery. When a bulk energy power system has warmed-up/activated, the module switches the power to the load from the performance battery to the bulk energy power system.