Abstract: Alkaline batteries are provided, including an anode, a cathode, and a separator disposed between the anode and cathode. The cathode porosity is selected to optimize performance characteristics of the battery. In one aspect, an alkaline cell is provided that includes (a) an anode, (b) a cathode, comprising a cathode active material, wherein the cathode has a porosity of from about 25% to about 30%, and (c) a separator disposed between the cathode and the anode.

Abstract: Alkaline batteries are provided, including an anode, a cathode, and a separator disposed between the anode and cathode. The cathode porosity is selected to optimize performance characteristics of the battery. In one aspect, an alkaline cell is provided that includes (a) an anode, (b) a cathode, comprising a cathode active material, wherein the cathode has a porosity of from about 25% to about 30%, and (c) a separator disposed between the cathode and the anode.

Abstract: AAA battery has a cathode having a height of at least 44.6 mm and/or an interior surface area of at least 1240 mm2. AAAA battery has a cathode having a height of at least 39.0 mm and/or an interior surface area of at least 795 mm2.

Abstract: Batteries are provided that include a tubular battery separator having a locally strengthened region. The strengthened region maybe provided by including a folded area adjacent an open end of the tubular separator.

Abstract: Batteries are disclosed. In some embodiments, a battery can include a housing including an aperture having an area of at most 0.008 square inch, an anode in the housing, a cathode in the housing, and a membrane. The membrane can cover at least a portion of the aperture, and can include at least one polymer. The membrane can have an area that is at most about 105 percent of the area of the aperture.

Abstract: And end cap assembly and venting system therein for closing and sealng the open end of a cell housing. The end cap assembly comprises a sealing disk underlying an end cap, and a metal support disk between the end cap and the sealing disk. The metal support disk has a plurality of primary vent apertures and a plurality of secondary vent apertures through its surface. The primary vent apertures are spaced apart along a path located at a greater distance from the central longitudinal axis of the metal support disk than the secondary vent apertures. The insulating sealing disk may have a thinned portion therein forming an rupturable membrane circumventing the central hub of the sealing disk. The insulating sealing disk may have protrusions emanating from its top surface to deflect the membrane during rupture. The venting system releases internal gases rapidly from the cell in the event of an abusive or short circuit discharge.

Abstract: An air manager system for a metal air cell is disclosed. The system includes: (a) a housing having an air mover and an air outlet opening; and (b) a cartridge that is removable from the housing.

Abstract: A method for controlling air flow in a metal air battery includes confining at least one metal air cell within a cartridge, which has an air inlet opening and an air outlet opening, and moving air through any of a plurality of air flow paths within the cartridge. Each of the paths passes through the air inlet opening of the cartridge, through a diffusion tube, through a distributor tube, across an active surface of at least one metal air cell, and through the air outlet opening of the cartridge, wherein all of the paths are substantially equal in length.

Abstract: A battery pack is described. The battery pack includes a DC to DC converter and a group of at least two primary cells. The DC-DC converter is operatively coupled to the group of primary cells. The group of primary cells have an initial voltage that is higher than a rated voltage for the battery pack. The DC-DC converter converts the voltage to a regulated nominal voltage that is lower that the rated voltage of the group of primary cells. By regulating the battery voltage down to a constant voltage, the cells can discharge down to a minimum voltage level per cell enabling additional energy transfer from the group of cells.

Abstract: A battery pack is described. The battery pack includes a DC to DC converter and a group of at least two primary cells. The battery pack also has an anti-charge circuit that inhibits charging current from charging the group of primary cells.