Abstract: A process for making a positive battery electrode material using a secondary metal. The secondary metal is preferably treated using an non-electrolytic process and formed into an active, positive battery electrode material by a precipitation reaction.

Abstract: A process for making a nickel hydroxide material without the necessity of a preamine reactor. The process includes the steps of providing a metal and forming the metal into an active positive electrode material. The process for making a nickel hydroxide material may also include one or more blending steps. The step for forming may include concurrently combining the metal with ammonium ions and hydroxide ions. The step for forming may also include a continuously stirred precipitation reaction of metal ions. In a preferred aspect of the process hereof, the metal may be a secondary nickel source, such as a spent or virgin electrolyte solution from a nickel electrorefining process, nickel electroless plating process or nickel electroplating process.

Abstract: A nickel hydroxide particle having a first active nickel hydroxide material and a second active nickel hydroxide material disposed about the first material, wherein the second active nickel hydroxide material has a mass at least 10% of the total particle mass. In a preferred embodiment of the invention the first active material and the second active material have a compositional difference of 1 to 25.

Abstract: High capacity, long cycle life positive electrode modified nickel hydroxide material for use in an alkaline rechargeable electrochemical cell at least one modifier and has modified activation energy, chemical potential and electrical conductivity. Particle size, particle size distribution, electrical conductivity have been controlled by introducing modifier elements throughout the bulk of the active material and by controlling process parameters.

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: A high capacity, long cycle life, positive electrode for use in an alkaline rechargeable electrochemical cell comprising: a solid solution nickel hydroxide material and carbon. The carbon acts to promote the multiphase structure and increase conductivity.

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.