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: The battery cell holder securely holds a plurality of electrical cells in a battery pack. The battery cell holder comprises at least two separate types of layers that are bound to each other to form opposing faces. The first layer is made of a material that absorbs aqueous solutions, particularly liquid electrolyte solutions used in metal-air cells, and preferably contacts an outward facing portion of each battery cell in the battery pack. This material acts to limit the spread of leaking electrolyte solution so that the electrolyte solution cannot spread to other cells and cause electrical short circuits between the cells in the battery pack. The second layer is made of a material that is light, flexible, inexpensive, electrically non-conductive and impermeable to liquids. The latter prevents seepage of absorbed electrolyte from the casing. The holder may be made of inexpensive materials and avoid a need for complete encapsulation of the cells.

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: The invention provides a metal-air electrochemical cell, having a leak-proof, metal prismatic casing comprising a pair of interfacing interengaging rectangular tray-like casing components, a first substantially rectangular tray-like casing component having a first major surface and contiguous side walls for encompassing a cathode of the cell and a second inverted substantially tray-like casing component having a second major surface and contiguous depending side walls for encompassing an anode of the cell, the side walls of one of the casing components being of a height to facilitate the curling and crimping of an upper portion thereof over a peripheral edge area of the major surface of the other casing component to form a leak-proof, closed prismatic casing.

Abstract: The invention provides a modular zinc air cell for use in an electrochemical zinc-air multi-cell battery, each cell being of the type provided with a housing having, two outer major surfaces, and two spaced-apart inner walls, the inner walls defining a first inner chamber for containing therein a zinc electrode, and in conjunction with the outer major surfaces defining two outer chambers for receiving reaction air; two generally planar, gas-permeable, but liquid-impermeable air electrodes, each of the electrodes being installed in a window-like opening provided in each of the inner walls, an electrolyte in contact with the zinc electrode and the air electrodes, and means for directing a flow of the reaction air into a first inlet provided in a first outer side surface of the housing through both of the outer chambers substantially in a uniform flow distribution across the outer faces of both of the air electrodes, and out of a second outlet provided in an opposite outer side surface of the housing.

Abstract: The invention provides An electrochemical zinc-air multi-cell battery, each cell being of the type provided with a housing having, two outer major surfaces, and two spaced-apart inner walls, the inner walls defining a first inner chamber for containing therein a zinc electrode, and in conjunction with the outer major surfaces defining two outer chambers for receiving reaction air; two generally planar, gas-permeable, but liquid-impermeable air electrodes, each of the electrodes being installed in a window-like opening provided in each of the inner walls, an electrolyte in contact with the zinc electrode and the air electrodes, means for directing a flow of the reaction air into a first inlet provided in a first outer side surface of the housing through both of the outer chambers substantially in a uniform flow distribution across the outer faces of both of the air electrodes, and out of a second outlet provided in an opposite outer side surface of the housing, and cooling air flow directing means for causing

Abstract: The invention provides a mechanically rechargeable, electrochemical metal-air battery of the type having a plurality of metal-air cells, each of the cells comprising a housing having a base, two major surfaces and two minor surfaces, defining an interior space for containing therein a metal electrode, the electrode having an electrically conductive skeletal member encompassed by a rigid static bed of active anode material and the skeletal member including a heat-conductive, plate-like portion extending above the bed of anode material. The battery further comprises air flow directing means positioned adjacent to the extending plate-like portion, for directing a flow of air towards the surfaces of the plate for the removal of heat therefrom by forced convection.