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: Provided is an alkaline battery wherein the cell casing has a concave shape and the middle of the cell casing creates greater pressure on the middle of the electrode stack than at the edges of the electrode stack. In one embodiment, the battery comprises a positive nickel electrode and a negative iron electrode.

Abstract: Provided is a Ni-Fe battery comprising a positive electrode, a negative electrode, electrolyte, and a polyolefin separator/inlay interposed between the positive and negative electrodes, with the separator/inlay having channels that allow movement of gas. In one embodiment, the separator/inlay has channels that exist in at least two planes.

Abstract: Provided is a Ni—Fe battery comprising an iron electrode which is preconditioned prior to any charge-discharge cycle. The preconditioned iron electrode used in the Ni—Fe battery is prepared by first fabricating an electrode comprising an iron active material, and then treating the surface of the electrode with an oxidant to thereby create an oxidized surface.

Abstract: Provided is a process for preparing an electrode comprising an iron active material. The process comprises first fabricating an electrode comprising an iron active material, and then treating the electrode with a gaseous oxidant to thereby create an oxidized surface. The resulting iron electrode is preconditioned prior to any charge-discharge cycle to have the assessable surface of the iron active material in the same oxidation state as in discharged iron negative electrodes active material.

Abstract: Provided is a process for preparing an electrode comprising an iron active material. The process comprises first fabricating an electrode comprising an iron active material, and then treating the surface of the electrode with water to thereby create an oxidized surface. The resulting iron electrode is preconditioned prior to any charge-discharge cycle to have the assessable surface of the iron active material in the same oxidation state as in discharged iron negative electrodes active material.

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 formed 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: Provided is a method of manufacturing a prismatic battery, or a series of prismatic batteries. The method comprises stacking positive electrode plates, negative electrode plates and separator layers therebetween. The positive and negative electrode plates extend beyond a periphery of the electrode stack. The positive electrode plates are fused to form a positive current collector, and the negative electrode plates are fused to form a negative current collector.

Abstract: Provided is a prismatic battery comprising stacked positive electrode plates, negative electrode plates and separator layers therebetween. The positive and negative electrode plates extend beyond a periphery of the electrode stack. The positive electrode plates are fused to form a positive current collector, and the negative electrode plates are fused to form a negative current collector. Both the positive and negative electrode plates comprise a metal foam and are compressed between about 42 and 45% of the original thickness.

Abstract: The present invention provides one with a Ni—Fe battery exhibiting enhanced power characteristics. The battery uses a particular electrolyte. The resulting characteristics of specific power and power density are much improved over conventional Ni—Fe batteries.

Abstract: Provided is a nickel-iron battery. The battery comprises a positive nickel electrode, an iron negative electrode, an electrolyte comprising a surfactant, and a non-polar separator. In one embodiment, the non-polar separator is comprised of a polyolefin, and the surfactant comprises a zwitterionic surfactant.

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: 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: 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: The present invention provides one with a novel coated iron electrode. Provided is an iron based electrode comprising a single layer conductive substrate coated on at least one side with a multilayered coating, with each coating layer comprising an iron active material, and preferably a binder. The coating is comprised of at least two layers. Each layer has at least a different porosity or composition than an adjacent layer. The iron based electrode is useful in alkaline rechargeable batteries, particularly as a negative electrode in a Ni—Fe battery.

Abstract: Provided is a battery comprising an iron electrode 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 M to 2.0 M, and the amount of metal sulfide present in the electrolyte ranges from 1 to 2% by weight.

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.