Abstract: The invention provides a substantially flat, planar, metal-air canless bi-cell having two major surfaces formed of oppositely-disposed spaced-apart gas-permeable liquid-impermeable air-electrode cathodic material, defining therebetween a space containing a fluid anodic material comprising anodic metal particles and electrolyte.

Abstract: A high capacity primary (single-use; non-rechargeable) battery pack for high current portable appliances such as cellular phones employs electrochemical cells that use ambient oxygen for one of the electrodes. The pack makes possible a simple low cost design by providing for oxygen supply in a completely passive yet compact configuration. Cells may be arranged inside a housing in a tightly packed arrangement by providing internal spaces that are sized to permit diffusion and, if possible, bulk air flow. The highest volumetric energy density is achievable by permitting bulk flow of air into the housing. It has been found that in practical use, in applications such as cellular telephones, that bulk air flow can play a significant role in gas exchange required for operation. A number of design criteria are developed for providing for a mix of molecular diffusion and bulk flow in the design of battery packs according to the invention.

Abstract: A method for maximizing the effective life and utilization of CO.sub.2 -absorbent material in a scrubber system for removing carbon dioxide from an air inflow to a metal-air battery or fuel cell comprises providing, in such a battery, a housing including a gas inlet, a gas outlet, and at least one removable, gas-permeable container containing a CO.sub.2 -absorbent material, the container being positioned across the flow path of gas entering said inlet and exiting said outlet. After a predetermined utilization of the system, the at least one removable, gas-permeable container is removed therefrom and spent CO.sub.2 -absorbent material from the container is regenerated for reuse in the scrubber system, the regeneration including at least periodically removing accumulated Group 1a metal carbonate deposits.

Abstract: The invention provides a process for preparing a gas-diffusion electrode for metal-air batteries and fuel cells of the type having a blocking layer formed from a precursor containing carbon black and particulate hydrophobic polymeric binders, comprising heating the carbon black at a temperature of about 400.degree.-1,200.degree. C. for a period of about 1-10 hours in a reducing environment, prior to the formation of the precursor, whereby hydrophilic centers in the pre-treated carbon black are minimized without increasing its corrosivity/surface area and thereby increasing the stability in concentrated KOH at high-cell operating temperatures of a blocking layer formed from the pre-treated carbon black.

Abstract: The invention provides a water-activated, deferred-action battery having a housing containing at least one cell, comprising at least one anode selected from the group consisting of magnesium, aluminum, zinc and alloys thereof; a cathode comprising a skeletal frame including conductive metal and having a portion of its surface area formed as open spaces, and further comprising a heat-pressed, rigid static bed of active cathode material encompassing the skeletal frame, the cathode material being formed of cuprous chloride, sulfur, carbon and a water-ionizable salt and being compacted and fused under pressure and heat to itself and to the skeletal frame, to form a heat-fused, conductive, electrochemically active phase; at least one cavity separating the cathode and the at least one anode, and at least one aperture leading to the at least one cavity for the ingress of an electrolyte-forming, aqueous liquid.

Abstract: The invention provides a single pass wet fabrication process for preparing a gas diffusion electrode for metal-air batteries and fuel cells comprising:a) preparing an active-layer forming dispersion containing catalyzed carbon black, hydrophilic fluorinated polymer and particulate hydrophobic fluorinated polymer in a liquid medium;b) preparing a blocking-layer forming dispersion containing carbon black and particulate hydrophobic polymeric binders in a liquid medium;c) filtering a first of the layer forming dispersions though filtering means to deposit a first layer of damp solids mass;d) filtering a second of the layer forming dispersions through the first deposited damp solids mass before the drying or sintering of the first deposited damp solids mass in order to deposit a second layer of damp solids mass thereon in such a manner that lower components of the second layer of damp solids mass are intermixed with upper components of the first layer of deposited damp solids mass;e) drying and compressing the co

Abstract: The invention provides a gas diffusion electrode containing a fiber reinforced composite structure in a layer thereof, the structure comprising structurally intact fibers precoated with sinterable polymeric material, which material is heat sintered, whereby the fibers are bonded to each other and to other components of the structure by the sintered polymeric material, while maintaining their individual fibrous structure and strength.

Abstract: The invention provides an electrode for use in a primary metal/air battery or in a hydrogen-oxygen fuel cell comprising a current-collecting metallic structure and a metallic foamed or fiber mat having a first surface attached to a first surface of the structure, a second surface of the mat being impregnated with an inner hydrophobic waterproof barrier layer coated with an outer active catalytic layer.