Abstract: A method of forming an air electrode of a metal-air battery includes forming at least a portion of the air electrode using a process selected from the group consisting of screen printing, spray printing, spin coating, and dip coating.

Abstract: A method of forming an air electrode of a metal-air battery includes forming a plurality of layers of the air electrode. The plurality of layers include an active layer and a gas diffusion layer. Forming the active layer includes forming a plurality of blank portions in a sublayer of the active layer for venting gases to the gas diffusion layer.

Abstract: Methods of forming an air electrode of a metal-air battery are provided. One method includes forming a plurality of layers of the air electrode. The plurality of layers include an active layer and a gas diffusion layer. Forming at least one of the active layer or the gas diffusion layer includes forming a first sublayer having a first concentration of a first material and forming a second sublayer having at least one of a second concentration of the first material that differs from the first concentration or a second material that differs from the first material. In another embodiment, a method includes forming a layer of an air electrode such that a gradient of a material is formed in at least a portion of the layer by varying a concentration of the material deposited between a first portion of the layer and a second portion of the layer.

Abstract: A method of producing all or a portion of an air electrode for a metal-air battery includes forming at least a portion of the air electrode using a process selected from the group consisting of an injection molding process and a screw extrusion process. This process may be used to form a gas diffusion layer of the air electrode, and active layer of the air electrode, or both. The air electrode may use polyethylene and/or polypropylene as a binder material in all or a portion of the air electrode.

Abstract: A metal-air flow battery is provided that comprises a tank configured to contain an anode paste material; a reaction tube in fluid communication with the tank, the reaction tube comprising an air electrode, an outer surface configured to allow air to enter the reaction tube, and an internal passage; and a mechanism for moving the anode paste material through the internal passage of the reaction tube.

Abstract: The present invention incorporates electronic components into an electronic core structure that may be readily hot laminated by existing processes. The structure may include multiple desired electronic components, such as a display, battery or other power source, integrated circuits, switches, magnetic stripe emulator, antenna, smart chips or other input devices. The structure includes laminated buffer layers to bridge layers and compensate for variation in electronic component dimensions. The structure may also incorporate battery packaging as part of the core layer structure and use printed electronic circuitry as part of the electronic core layers to impart the desired characteristics. A variety of components may be incorporated in the structure.