Abstract: A metal-air battery assembly having plurality of free standing metal-air cells forming a cell group within a battery case assembly. Each free standing cell has flexible, compressible walls capable of containing electrolyte, the walls comprising air cathodes including cathode current distributors. Each cell has a split anode assembly and current. The anode assembly has one or more reactive anode fuel plates and an anode current collector. Each of the cells is free standing and easily replaced. The battery case assembly has a mechanism for compressing the cells when the lid is closed and releasing the cell group for servicing when the lid is open.

Abstract: A method of controlling a power generating system comprising a plurality of metal-air cells and a pump for circulating an electrolyte solution through the cells. The method comprises sensing an operating condition of the generating system, and selectively energizing the pump as a function of the sensed operating condition whereby energizing the pump causes the electrolyte solution to be circulated through the cells.

Abstract: An electrochemical power generating system has a base unit and a replaceable fuel unit. The base unit comprises controller for controlling operation of the pump. The fuel unit comprises a second housing releasably connectable to the first housing and a row of metal-air cells in the second housing electrically inter-connected together. Each cell includes a casing, a metal anode within the casing, an air cathode, a spacer between the cathode and anode for preventing the anode from contacting the cathode, an electrolyte intake port and an electrolyte discharge port in the casing for passage of electrolyte through the casing and between the anode and cathode. The fuel unit further comprises a manifold, an electrolyte reservoir, and a fluid line. The manifold has an intake port and a plurality of discharge ports in fluid communication with the electrolyte intake ports of the cells so that electrolyte flowing through the manifold is directed through the intake ports of the cells.

Abstract: A metal air cell comprising a flexible, recloseable, pouch made of a gas-permeable, electrolyte-impermeable, material forming the cathode of the cell, a metal plate anode in the pouch, and spacers physically isolating the anode from the interior of the flexible pouch cathode, the spacers separating the anode and the cathode by a predetermined spacing. A plurality of such cells are preferably stacked into a multicell battery, and compressed in a harness to maintain proper anode-cathode spacing as the anode is consumed. The stack can be incorporated as a replaceable part of a larger power system including a circulatory system for circulating an electrolyte solution through the cells in the stack. A controller controls the circulatory system, particularly during start-up and shut-down, to achieve a fast start up, and an efficient shut down.