Patents Assigned to ZAF Energy Systems, Incorporated
  • Patent number: 11404696
    Abstract: A green secondary electrode includes a conductive substrate, active material and material additives in direct contact with the conductive substrate, and a combination of vinyl acetate-ethylene and methylcellulose-based additive binding the conductive substrate, active materials, and material additives together. The green secondary electrode may be a positive electrode or a negative electrode.
    Type: Grant
    Filed: January 5, 2022
    Date of Patent: August 2, 2022
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Hannah S. Smith, Melissa D. McIntyre, Adam Weisenstein, Andrew F. Souder, II
  • Patent number: 11404747
    Abstract: A zinc-based battery includes a non-sintered separator system including a polymer separator and a coating on the polymer separator. The coating includes cellulose acetate that prevents metallic zinc penetration into the separator, and ceria bound with the cellulose acetate that chemically oxidizes metallic zinc to zinc oxide.
    Type: Grant
    Filed: February 18, 2022
    Date of Patent: August 2, 2022
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Adam Weisenstein, Allen Charkey, Melissa D. McIntyre
  • Patent number: 11367914
    Abstract: A metal air battery cell has a sealed pouch defined by a metallocene film and a gas and liquid impermeable flexible layer, and an electrochemical cell contained within the pouch. The metallocene film and gas and liquid impermeable flexible layer are sealed to each other and around the electrochemical cell.
    Type: Grant
    Filed: November 5, 2021
    Date of Patent: June 21, 2022
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Adam Weisenstein, William A. Garcia, Joel Ballard, Sean Barrett, Melissa D. McIntyre
  • Patent number: 11329335
    Abstract: A metal air battery cell has a sealed pouch defined by a metallocene film and a gas and liquid impermeable flexible layer, and an electrochemical cell contained within the pouch. The metallocene film and gas and liquid impermeable flexible layer are sealed to each other and around the electrochemical cell.
    Type: Grant
    Filed: November 5, 2021
    Date of Patent: May 10, 2022
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Adam Weisenstein, William A. Garcia, Joel Ballard, Sean Barrett, Melissa D. McIntyre
  • Patent number: 11322729
    Abstract: A method for manufacturing zinc negative electrodes includes mixing a powder including zinc with polytetrafluoroethylene to form a homogenous blend, injecting a lubricant into the homogenous blend to form a dough, kneading the dough to form a fibrillated dough, and extruding the fibrillated dough through a die to form a ribbon. The method also includes calendering the ribbon to a target thickness to form a plaque, drying the plaque to form an active material sheet, laminating portions of the active material sheet to a current collector substrate to form an electrode blank, and sectioning the electrode blank into zinc negative electrodes.
    Type: Grant
    Filed: November 5, 2021
    Date of Patent: May 3, 2022
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Michael J. Gordon, Shiloh J. Williams, Allen Charkey, Andrew Souder, II
  • Patent number: 11258103
    Abstract: A zinc alkaline secondary battery includes a positive electrode, a negative electrode including a multi-valent oxide species, a separator system disposed between the electrodes, and an alkaline electrolyte in contact with the negative electrode. The alkaline electrolyte includes hexametaphosphate salt and zinc acetate. Ligands from the hexametaphosphate salt and zinc acetate are anchored to the negative electrode via chelation sites created by the multi-valent oxide species.
    Type: Grant
    Filed: March 16, 2020
    Date of Patent: February 22, 2022
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Melissa D. McIntyre, Ernest Rimanosky, Adam Weisenstein, Cody R. Carter, Allen Charkey
  • Patent number: 11228065
    Abstract: A secondary battery recombination system includes catalyst and hydrophobic gas diffusion layers defining an electrode that recombines hydrogen and oxygen into water, and a scaffold encapsulating and in non-bonded contact with the electrode. The electrode may be carbon cloth, carbon felt, carbon foam, or carbon paper. The scaffold may be expanded metal or perforated foil.
    Type: Grant
    Filed: July 2, 2021
    Date of Patent: January 18, 2022
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Adam Weisenstein, William A. Garcia, Melissa D. McIntyre, Eivind Listerud
  • Patent number: 11228032
    Abstract: An electrochemical component has a green secondary electrode including a conductive substrate, homogeneous pre-synthesized calcium zincate in direct contact with the conductive substrate, and a combination of styrene-butadiene rubber and sintered polytetrafluoroethylene binding the conductive substrate and calcium zincate together.
    Type: Grant
    Filed: April 6, 2021
    Date of Patent: January 18, 2022
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Hannah S. Smith, Andrew F. Souder, II, Adam Weisenstein, Michael J. Gordon, Melissa D. McIntyre
  • Patent number: 11205772
    Abstract: A method for manufacturing zinc negative electrodes includes mixing a powder including zinc with polytetrafluoroethylene to form a homogenous blend, injecting a lubricant into the homogenous blend to form a dough, kneading the dough to form a fibrillated dough, and extruding the fibrillated dough through a die to form a ribbon. The method also includes calendering the ribbon to a target thickness to form a plaque, drying the plaque to form an active material sheet, laminating portions of the active material sheet to a current collector substrate such that the current collector substrate is sandwiched between the portions to form an electrode blank, and sectioning the electrode blank into zinc negative electrodes.
    Type: Grant
    Filed: May 13, 2021
    Date of Patent: December 21, 2021
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Michael J. Gordon, Shiloh J. Williams, Allen Charkey, Andrew Souder, II
  • Patent number: 11128002
    Abstract: Monobloc batteries include compartments containing cells. Terminals extend into the compartments and are electrically connected with the cells via tabs. The tabs are folded to form bent stacks and include openings in partial registration with each other. The terminals extend through the openings and are secured to the tabs. The terminals are off-center relative to the compartments to preserve space for the bent stacks.
    Type: Grant
    Filed: February 12, 2019
    Date of Patent: September 21, 2021
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Michael J. Gordon, Shiloh J. Williams, Michael T. Shireman, Eivind Listerud, Adam Weisenstein, Randy Moore
  • Patent number: 10944113
    Abstract: An electrode includes a current collector, a metal shell in direct contact with and encapsulating the current collector, green dendritic columnar growths extending out of the metal shell and having protrusions thereon, and active material in contact with the metal shell and having embedded therein the green dendritic columnar growths. The protrusions penetrate the active material to form a mechanical retainer that prevents delamination of the active material from the metal shell and define localized regions of increased current density during operation of the electrode that promote deposition of the active material first on the protrusions and then on areas of the green dendritic columnar growths adjacent to the protrusions such that the active material electrochemically adheres to the green dendritic columnar growths and the protrusions enlarge during repeated charge and discharge cycling of the electrode.
    Type: Grant
    Filed: February 27, 2020
    Date of Patent: March 9, 2021
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Melissa D. McIntyre, Adam Weisenstein, Kurt Salloux
  • Patent number: 10777781
    Abstract: Monobloc batteries include compartments containing cells. Terminals extend into the compartments and are electrically connected with the cells via tabs. The tabs are folded to form bent stacks and include openings in partial registration with each other. The terminals extend through the openings and are secured to the tabs. The terminals are off-center relative to the compartments to preserve space for the bent stacks.
    Type: Grant
    Filed: October 2, 2019
    Date of Patent: September 15, 2020
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Michael J. Gordon, Shiloh J. Williams, Michael T. Shireman, Eivind Listerud, Adam Weisenstein, Randy Moore
  • Patent number: 10658675
    Abstract: An electrode includes a current collector having metallic struts formed by freeze tape casting along a cast direction, and an electrochemically active material occupying portions of the void spaces. The struts define a percolated conductive network and void spaces through the percolated conductive network. The struts are directionally aligned and the void spaces are directionally ordered perpendicular to the cast direction.
    Type: Grant
    Filed: November 1, 2018
    Date of Patent: May 19, 2020
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Adam Weisenstein, Allen Charkey, Melissa D. McIntyre
  • Patent number: 10651445
    Abstract: An electrode assembly includes an electrode saturated with electrolyte, and one or more ionically conductive and electronically insulating cellulose acetate coatings forming a continuous and conformal film adhered to and encapsulating the electrode.
    Type: Grant
    Filed: January 23, 2018
    Date of Patent: May 12, 2020
    Assignee: ZAF Energy Systems, Incorporated
    Inventors: Sean Barrett, Adam Weisenstein, Cody R. Carter, William A. Garcia
  • Patent number: 10637118
    Abstract: A metal-air battery cell includes an electrode assembly and a sealed pouch. The electrode assembly includes an air electrode, a negative electrode, a separator in contact with and disposed between the electrodes, and a hydrophobic gas diffusion layer in contact with a side of the air electrode opposite the separator. The pouch envelops the electrode assembly and contains an electrolyte therein. The pouch is defined by a gas permeable hydrophobic flexible layer in contact with the hydrophobic gas diffusion layer. The electrode assembly further includes a terminal extending from and away at least one of the electrodes, and through the pouch. Opposing sides of the pouch are sealed to each other and around the terminal.
    Type: Grant
    Filed: May 17, 2019
    Date of Patent: April 28, 2020
    Assignee: ZAF Energy Systems, Incorporated
    Inventors: Adam Weisenstein, Paula J. Kosted, Joel Ballard, Sean Barrett, William A. Garcia
  • Patent number: 10511059
    Abstract: A battery cell includes an electrode assembly having a negative electrode, positive electrode, and separator bathed in an alkaline electrolyte, a pouch encapsulating the electrode assembly, and first and second tabs respectively extending from the positive and negative electrodes through the pouch. The first tab has thereon a coating including acrylic paint and the second tab has thereon a coating including lacquer to discourage creepage of the alkaline electrolyte along the first and second tabs and out of the pouch.
    Type: Grant
    Filed: November 15, 2018
    Date of Patent: December 17, 2019
    Assignee: ZAF Energy Systems, Incorporated
    Inventors: Adam Weisenstein, Allen Charkey, Melissa D. McIntyre, Blaine D. Latimer, Benjamin J. Washburn
  • Patent number: 10297889
    Abstract: A metal-air battery cell includes an electrode assembly and a sealed pouch. The electrode assembly includes an air electrode, a negative electrode, a separator in contact with and disposed between the electrodes, and a hydrophobic gas diffusion layer in contact with a side of the air electrode opposite the separator. The pouch envelops the electrode assembly and contains an electrolyte therein. The pouch is defined by a gas permeable hydrophobic flexible layer in contact with the hydrophobic gas diffusion layer, and a gas and liquid impermeable flexible layer in contact with the negative electrode. The electrode assembly further includes a terminal extending from and away at least one of the electrodes, and through the pouch. The layers of the pouch are sealed to each other and around the terminal.
    Type: Grant
    Filed: May 27, 2016
    Date of Patent: May 21, 2019
    Assignee: ZAF ENERGY SYSTEMS, INCORPORATED
    Inventors: Adam Weisenstein, Paula J. Kosted, Joel Ballard, Sean Barrett
  • Patent number: 9099753
    Abstract: A metal-air battery includes a canister and a spiral wound electrode assembly disposed within the canister. The electrode assembly includes an ion permeable and substantially gas impermeable anode, a catalytic cathode, and a dielectric separator disposed between the anode and cathode.
    Type: Grant
    Filed: August 16, 2013
    Date of Patent: August 4, 2015
    Assignee: ZAF Energy Systems, Incorporated
    Inventors: Ronald D. Brost, Kristine M. Brost, Matthew J. Cottrell, Howard F. Wilkins
  • Patent number: 8871394
    Abstract: A metal-air battery according to the present disclosure includes an electrode assembly with a first electrode layer having a length and being folded lengthwise, and a gas diffusion layer having a length that is approximately half the length of the first electrode layer. Furthermore, the gas diffusion layer is positioned proximate the first electrode layer or between first and second portions of the first electrode layer.
    Type: Grant
    Filed: March 7, 2014
    Date of Patent: October 28, 2014
    Assignee: ZAF Energy Systems, Incorporated
    Inventors: William A. Garcia, Howard F. Wilkins
  • Patent number: 8728671
    Abstract: A positive electrode may include an electrically conductive scaffold, conductive catalytic A-site deficient perovskite particles chemically bonded to the scaffold, an ion and gas permeable ionomer connecting the particles, and a hydrophobic porous layer on the scaffold. A secondary air electrode may include conductive bi-functional catalytic A-site deficient perovskite particles including AI-site lanthanum cations and AII-site alkaline earth metal cations, an ion and gas permeable ionomer connecting the particles, and a conductive scaffold in electrical contact with the particles.
    Type: Grant
    Filed: June 5, 2013
    Date of Patent: May 20, 2014
    Assignee: ZAF Energy Systems, Incorporated
    Inventors: Ronald D. Brost, Adam Weisenstein, Kristine M. Brost, Howard F. Wilkins, Randolph M. Kosted