Abstract: Provided is a process for preparing an electrode comprising an iron active material. The process comprises first fabricating an electrode comprising an iron active material, and then treating the surface of the electrode with an oxidant to thereby create an oxidized surface. The resulting iron electrode is preconditioned prior to any charge-discharge cycle to have the assessable surface of the iron active material in the same oxidation state as in discharged iron negative electrodes active material.

Abstract: Provided is a process for preparing an electrode comprising an iron active material. The process comprises first fabricating an electrode comprising an iron active material, and then treating the electrode with a gaseous oxidant to thereby create an oxidized surface. The resulting iron electrode is preconditioned prior to any charge-discharge cycle to have the assessable surface of the iron active material in the same oxidation state as in discharged iron negative electrodes active material.

Abstract: Provided is a process for preparing an electrode comprising an iron active material. The process comprises first fabricating an electrode comprising an iron active material, and then treating the surface of the electrode with an oxidant solution to thereby create an oxidized surface. The resulting iron electrode is thereby preconditioned prior to any charge-discharge cycle to have the assessable surface of the iron active material in the same oxidation state as in discharged iron negative electrodes active material.

Abstract: Provided is a process for preparing an electrode comprising an iron active material. The process comprises first fabricating an electrode comprising an iron active material, and then treating the surface of the electrode with water to thereby create an oxidized surface. The resulting iron electrode is preconditioned prior to any charge-discharge cycle to have the assessable surface of the iron active material in the same oxidation state as in discharged iron negative electrodes active material.

Abstract: Provided is a flat plate electrode cell, comprises positive electrode plates and negative electrode plates. The positive electrode plates each comprise manganese and compressed metal foam. The negative electrode plates each comprise zinc and compressed metal foam. Both the positive and negative electrodes can have alignment tabs, wherein the flat plate electrode cell can further comprise electrical terminals tanned from the aligned tabs. The rechargeable flat plate electrode cell of the present disclosure, formed from compressed metal foam, provides both low resistance and high rate performance to the electrodes and the cell. Examples of improvements over round bobbin and flat plate cells are current density, memory effect, shelf life, charge retention, and voltage level of discharge curve. In particular, the rechargeable flat plate electrode cell of the present disclosure provides longer cycle life with reduced capacity fade as compared with known round bobbin and flat plate cells.

Abstract: Provided is a Mn—Fe battery comprising an iron based anode and a manganese cathode. The manganese cathode comprises a compressed metal foam substrate with the manganese active material present throughout the substrate. The metal foam substrate containing the manganese active material is also compression sized between about 42 and 45%.

Abstract: Provided is a Mn—Fe battery comprising an iron based electrode comprising a single layer of a conductive substrate coated on at least one side with a coating comprising an iron active material and a binder. The electrode can be prepared by continuously coating each side of the substrate with a coating mixture comprising the iron active material and binder.

Abstract: Provided is a method of manufacturing a prismatic battery, or a series of prismatic batteries. The method comprises stacking positive electrode plates, negative electrode plates and separator layers therebetween. The positive and negative electrode plates extend beyond a periphery of the electrode stack. The positive electrode plates are fused to form a positive current collector, and the negative electrode plates are fused to form a negative current collector.

Abstract: Provided is a continuous process for preparing a high quality and high performance iron electrode. The process comprises preparing a formulation comprising an iron active material and a binder and coating a continuous substrate material on a least one side with the formulation. The coated continuous substrate material is dried, compacted and blanked. A tab is then attached to the electrode.

Abstract: Provided is an iron based electrode comprising a single layer of a conductive substrate coated on at least one side with a coating comprising an iron active material and a binder. The iron based electrode is useful in a Ni—Fe battery as the anode. The electrode can also be prepared by continuously coating each side of the substrate with a coating mixture comprising the iron active material and binder.

Abstract: Providing is a battery comprising an iron anode, a nickel cathode, and an electrolyte comprised of sodium hydroxide, lithium hydroxide and a soluble metal sulfide. In one embodiment the concentration of sodium hydroxide in the electrolyte ranges from 6.0 M to 7.5 M, the amount of lithium hydroxide present in the electrolyte ranges from 0.5 to 2.0 M, and the amount of metal sulfide present in the electrolyte ranges from 1-2% by weight.

Abstract: Provided is a Ni—Fe battery comprising a high quality, high performance iron electrode. In one embodiment the iron electrode comprises a polyvinyl alcohol binder. The iron electrode of the Ni—Fe battery comprises a single conductive substrate coated on one or both sides with an iron active material.

Abstract: Provided is a battery comprising an iron electrode and an electrolyte comprised of sodium hydroxide, lithium hydroxide and a soluble metal sulfide. In one embodiment, the concentration of sodium hydroxide in the electrolyte ranges from 6.0 M to 7.5 M, the amount of lithium hydroxide present in the electrolyte ranges from 0.5 M to 2.0 M, and the amount of metal sulfide present in the electrolyte ranges from 1 to 2% by weight.

Abstract: The present invention provides one with an iron electrode employing a binder comprised of polyvinyl alcohol (PVA) binder. In one embodiment, the invention comprises an iron based electrode comprising a single layer of a conductive substrate coated on at least one side with a coating comprising an iron active material and a binder, wherein the binder is PVA. This iron based electrode is useful in alkaline rechargeable batteries, particularly as a negative electrode in a Ni—Fe battery.

Abstract: Provided is a high quality and high performance iron electrode, which is prepared by a continuous process. The process comprises preparing a formulation comprising an iron active material and a binder, and coating a continuous substrate material on at least one side with the formulation. The coated continuous substrate material is dried, compacted and blanked. A tab is then attached to the electrode. In one embodiment, the iron electrode comprises a PVA binder.

Abstract: The present invention provides one with a novel coated iron electrode. Provided is an iron based electrode comprising a single layer conductive substrate coated on at least one side with a multilayered coating, with each coating layer comprising an iron active material, and preferably a binder. The coating is comprised of at least two layers. Each layer has at least a different porosity or composition than an adjacent layer. The iron based electrode is useful in alkaline rechargeable batteries, particularly as a negative electrode in a Ni—Fe battery.

Abstract: Provided is a flat plate electrode cell, comprises positive electrode plates and negative electrode plates. The positive electrode plates each comprise manganese and compressed metal foam. The negative electrode plates each comprise zinc and compressed metal foam. Both the positive and negative electrodes can have alignment tabs, wherein the flat plate electrode cell can further comprise electrical terminals tanned from the aligned tabs. The rechargeable flat plate electrode cell of the present disclosure, formed from compressed metal foam, provides both low resistance and high rate performance to the electrodes and the cell. Examples of improvements over round bobbin and flat plate cells are current density, memory effect, shelf life, charge retention, and voltage level of discharge curve. In particular, the rechargeable flat plate electrode cell of the present disclosure provides longer cycle life with reduced capacity fade as compared with known round bobbin and flat plate cells.

Abstract: Provided is a method of manufacturing a prismatic battery, or a series of prismatic batteries. The method comprises stacking positive electrode plates, negative electrode plates and separator layers therebetween. The positive and negative electrode plates extend beyond a periphery of the electrode stack. The positive electrode plates are fused to form a positive current collector, and the negative electrode plates are fused to form a negative current collector.

Abstract: A two-ply core for core wound paper products. The inner ply of the core has more resistance to compression than the outer ply. The outer ply may have more resistance to tension than the inner ply. The two-ply core is suitable for use with core-wound paper products and particularly those which have been diametrically compressed. The core may comprise two plies of differing basis weights, wherein the inner ply has a greater basis weight than the outer ply.

Abstract: Disclosed is a compressed core-wound paper product such as toilet tissue or paper towels. The core-wound paper product comprises a paper product wound about a generally tubular core. The core-wound paper product is compressed, so that the core is flattened to form vertices. By selecting the proper combination of core materials and thickness, to form a core of the proper stiffness; paper product caliper and quantity, to provide hoop forces against the core which are not too great; and total packaging dimensions, so that the core-wound paper product is not too tightly constrained, the core-wound paper product may be made to open to an inside core dimension of about 0.16 centimeters (0.06 inches) to about 1.27 centimeters (0.5 inches). The invention may be utilized with either single roll or multiple roll packages.