Abstract: Battery cells having lithium intercalation anodes protected by surface coatings and active sulfur cathodes, and methods for their fabrication, provide improved battery cell performance.

Abstract: A novel carbonaceous electrode support material is disclosed characterized by a corrosion rate of 0.03 wt. %/hour or less when measured a5 550 millivolts vs. a Hg/HgO electrode in a 30 wt. % KOH electrolyte a5 30.degree. C. The electrode support material comprises a preselected carbon black material which has been heat-treated by heating the material to a temperature of from about 2500.degree. to about 3000.degree. C. over a period of from about 1 to about 5 hours in an inert atmosphere and then maintaining the preselected carbon black material at this temperature for a period of at least about 1 hour, and preferably about 2 hours, in the inert atmosphere.A carbonaceous electrode suitable for use as an air electrode in a metal-air cell may be made from the electrode support material by shaping and forming it into a catalyst support and then impregnating it with a catalytically active material capable of catalyzing the reaction with oxygen at the air electrode of metal-air cell.

Abstract: An improved zinc electrode is disclosed for a rechargeable zinc-air battery comprising an outer frame and a porous foam electrode support within the frame which is treated prior to the deposition of zinc thereon to inhibit the formation of zinc dendrites on the external surface thereof. The outer frame is provided with passageways for circulating an alkaline electrolyte through the treated zinc-coated porous foam. A novel rechargeable zinc-air battery system is also disclosed which utilizes the improved zinc electrode and further includes an alkaline electrolyte within said battery circulating through the passageways in the zinc electrode and an external electrolyte circulation means which has an electrolyte reservoir external to the battery case including filter means to filter solids out of the electrolyte as it circulates to the external reservoir and pump means for recirculating electrolyte from the external reservoir to the zinc electrode.