Abstract: A method for producing a structurally modified nickel hydroxide active material for the positive electrode of an alkaline electrochemical cell. The method comprises the steps of combining a nickel ion solution, an ammonium hydroxide solution, and an alkali metal hydroxide solution to form a reaction mixture; and cycling the supersaturation of the reaction mixture.

Abstract: Mechanically and thermally improved rechargeable batteries, modules and fluid-cooled battery pack systems. The battery is prismatic in shape with an optimized thickness to width to height aspect ratio which provides the battery with balanced optimal properties when compared with prismatic batteries lacking this optimized aspect ratio. The optimized thickness, width and height allow for maximum capacity and power output, while eliminating deleterious side affects. The battery case design allows for unidirectional expansion which is readily compensated for by applying external mechanical compression counter to that direction. In the module, the batteries are bound within a module bundling/compression means under external mechanical compression which is optimized to balance outward pressure due to expansion and provide additional inward compression to reduce the distance between the positive and negative electrodes, thereby increasing overall battery power.

Abstract: A high capacity long cycle life positive electrode which includes an electronically conductive substrate for conducting electricity through the electrode and an electrochemically active nickel hydroxide material in electrical contact with the electronically conductive substrate, the electrochemically active nickel hydroxide material is composed of at least two different solid solution nickel hydroxide materials each having differing compositions. The positioning of the at least two different solid solution nickel hydroxide materials and their relative compositions alter the local redox potential or porosity to force discharge of the electrode in a stepwise fashion from the nickel hydroxide material remote from said conductive network or substrate, through any intermediate nickel hydroxide materials, to the nickel hydroxide material adjacent the conductive network or substrate.

Abstract: Nickel-metal hydride batteries and electrodes are capable of increased power output and recharge rates. The electrodes and batteries produced therefrom exhibit increased internal conductance. The positive and negative electrodes may be formed by pressing powdered metal-hydride active materials into porous metal substrates. The porous metal substrates are formed from copper, copper-plated nickel, or a copper-nickel alloy, and may be additionally plated with a material which is electrically conductive and resistant to corrosion in the battery environment, such as nickel.

Abstract: Nickel-metal hydride batteries and electrodes capable of increased power output and recharge rates. The positive and negative electrodes may be formed by pressing powdered metal-hydride active materials into porous metal substrates. The porous metal substrates are formed from copper, copper-plated nickel, or a copper-nickel alloy. The electrode tab are directly attached to the porous metal substrate via a low electrical-resistance connection which includes welding, brazing, or soldering.

Abstract: Disordered multicomponent hydrogen storage material characterized by extraordinarily high storage capacity due to a high density of useable hydrogen storage sites (greater than 10.sup.23 defect sites/cc) and/or an extremely small crystallite size. The hydrogen storage material can be employed for electrochemical, fuel cell and gas phase applications. The material may be selected from either of the modified LaNi.sub.5 or modified TiNi families formulated to have a crystallite size of less than 200 Angstroms and most preferably less than 100 Angstroms.

Abstract: A robust terminal for a prismatic battery comprising a terminal post, and a connector strap mechanically joined to the terminal post. Electrode tabs are mechanically joined to the connector strap. Connection points between the tabs and the connector strap have two or more degrees of freedom.

Abstract: An apparatus for monitoring a battery pack having a plurality of serially connected rechargeable batteries. The apparatus comprises a means of detecting cell reversal and a means of protecting the batteries of the battery pack upon detection of cell reversal.

Abstract: A slurry loading apparatus for automatically loading a slurry into a substrate, the substrate having a front surface, a back surface opposite said front surface and an interior with voids between the front and back surfaces, the apparatus including a device for introducing the slurry onto the front surface and into the voids where excess slurry passes through the substrate and exits the back surface, and a device for repeatedly forcing the excess slurry back onto the back surface and into the voids.

Abstract: A positive electrode for use in alkaline rechargeable electrochemical cells comprising: a material comprising a compositionally and structurally disordered multiphase nickel hydroxide host matrix which includes at least one modifier.

Abstract: A disordered multicomponent MgNi based electrochemical hydrogen storage material having a microstructure including a substantial volume fraction characterized by intermediate range order and exhibiting extraordinarily high storage capacity and methods of fabricating same.

Abstract: A disordered positive electrode for use in an alkaline rechargeable electrochemical cell comprising: a solid solution nickel aluminum hydroxide material having a multiphase structure. This solid solution nickel hydroxide material is a multiphase structure that comprises at least one microcrystalline .alpha.-phase material. Phase stabilizers and conductivity enhancers can be included to further stabilize the material.

Abstract: A sealed prismatic metal hydride battery greater than 10 Ah in size comprising a battery case of high thermal conductivity; and at least one bundle of metal hydride electrodes of high thermal conductivity in thermal contact with said battery case. Batteries according to the invention prevent the accumulation of heat that can damage nickel metal hydride batteries particularly during overcharge.

Abstract: Non-uniform heterogeneous powder particles for electrochemical uses, and said powder particles comprising at least two separate and distinct hydrogen storage alloys selected from the group consisting of: Ovonic LaNi.sub.5 type alloys, Ovonic TiNi type alloys, and Ovonic MgNi based alloys.

Abstract: A solid state battery comprising a substrate; at least one multilayered electrochemical cell deposited onto the substrate, each layer of the multilayered electrochemical cell composing: a layer of negative electrode material capable of electrochemically adsorbing and desorbing ions during charge and discharge; a layer of positive electrode material capable of electrochemically desorbing and adsorbing ions during charge and discharge; and a layer of insulating/conducting material disposed between the layer of positive electrode material and the layer of negative electrode material, where the layer of insulating/conducting material is electrically insulating and capable of readily conducting or transposing ions from the layer positive electrode material to the layer of negative electrode material while the battery is charging and from the layer of negative electrode material to the layer of positive electrode material while the battery is discharging; and an electrically conductive layer deposited a top the las

Abstract: A disordered electrochemical hydrogen storage alloy comprising:(Base Alloy).sub.a Co.sub.b Mn.sub.c Fe.sub.d Sn.sub.ewhere the Base Alloy comprises 0.1 to 60 atomic percent Ti, 0.1 to 40 atomic percent Zr, 0 to 60 atomic percent V, 0.1 to 57 atomic percent Ni, and 0 to 56 atomic percent Cr; b is 0 to 7.5 atomic percent; c is 13 to 17 atomic percent; d is 0 to 3.5 atomic percent; e is 0 to 1.5 atomic percent; and a+b+c+d+e=100 atomic percent.

Abstract: A positive electrode material for use in electrochemical cells. This material comprises particles of positive electrode material including at least one electrochemically active hydroxide and a substantially continuous, uniform, encapsulant layer surrounding the particles of positive electrode material. The encapsulant layer is formed from a material which, upon oxidation during processing or during charging of the electrode, is convertible to a highly conductive form, and which, upon subsequent discharge of the electrode, does not revert to its previous form. Preferably, the electrochemically active hydroxide includes at least nickel hydroxide. The encapsulant layer is preferably formed from at least cobalt hydroxide or cobalt oxyhydroxide. This layer is formed on the particles of positive electrode material by precipitation from a cobalt salt solution, which can be a cobalt sulfate solution. Also disclosed are positive electrodes including the material and a precipitation method of forming the material.

Abstract: A solid state battery comprising a substrate; at least one multilayered electrochemical cell deposited onto the substrate, each layer of the multilayered electrochemical cell composing: a layer of negative electrode material capable of electrochemically adsorbing and desorbing ions during charge and discharge; a layer of positive electrode material capable of electrochemically desorbing and adsorbing ions during charge and discharge; and a layer of insulating/conducting material disposed between the layer of positive electrode material and the layer of negative electrode material, where the layer of insulating/conducting material is electrically insulating and capable of readily conducting or transporting ions from the layer positive electrode material to the layer of negative electrode material while the battery is charging and from the layer of negative electrode material to the layer of positive electrode material while the battery is discharging; and an electrically conductive layer deposited a top the la

Abstract: An electrochemical hydrogen storage material comprising:(Base Alloy).sub.a M.sub.bwhere, Base Alloy is an alloy of Mg and Ni in a ratio of from about 1:2 to about 2:1, preferably 1:1; M represents at least one modifier element chosen from the group consisting of Co, Mn, Al, Fe, Cu, Mo, W, Cr, V, Ti, Zr, Sn, Th, Si, Zn, Li, Cd, Na, Pb, La, Mm, and Ca; b is greater than 0.5, preferably 2.5, atomic percent and less than 30 atomic percent; and a+b=100 atomic percent. Preferably, the at least one modifier is chosen from the group consisting of Co, Mn, Al, Fe, and Cu and the total mass of the at least one modifier element is less than 25 atomic percent of the final composition. Most preferably, the total mass of said at least one modifier element is less than 20 atomic percent of the final composition.

Abstract: A sealed battery case comprising: a case of formable metal; a lid for the case, the lid having an annular shroud defining the periphery of at least one opening; at least one terminal having a sealing lip at its circumference; where the terminal is crimp sealed into said annular shroud. Also described is a method of attaching a terminal in a lid opening of a battery case; the opening having an opening and an annular shroud surrounding the opening. The annular shroud is of an inner diameter slightly larger than the diameter of the opening and extending outward from the lid, and the terminal has a diameter smaller than the diameter of the opening and a sealing lip around its circumference. The sealing lip has a diameter in between the diameter of the opening and the diameter of the shroud; the method comprising the steps of: placing a seal of an insulating material; around the sealing lip; inserting the terminal into the shroud; and crimping the shroud around the seal.