Abstract: A battery and an associated method are provided for generating power using an air cathode battery with a slurry anode. The method provides a battery with an air cathode separated from an anode current collector by an electrically insulating separator and an extrusion gap. The anode current collector extruder has a first plate with a plurality of slurry outlet perforations, and a sleeve having a first partition immediately adjacent to the extruder first plate, with a plurality of slurry inlet perforations. Active slurry is provided under pressure to an extruder inlet, and the extruder first plate slurry outlet perforations are selectively aligned with sleeve first partition slurry inlet perforations. Active slurry deposits are formed in the extrusion gap to mechanically charge the battery. In the discharge position, the sleeve moves so that the perforations no longer align, and slurry in the extruder is isolated from slurry in the extrusion gap.

Abstract: A method is provided for cycling power in a transition metal cyanometallate (TMCM) cathode battery. The method provides a battery with a TMCM cathode, an anode, and an electrolyte, where TMCM corresponds to the chemical formula of AXM1NM2M(CN)Y-d(H2O), where “A” is an alkali or alkaline earth metal, and where M1 and M2 are transition metals. The method charges the battery using a first charging current, or greater. In response to the charging current, a plating of “A” metal is formed overlying a plating surface of the anode. In response to discharging the battery, the “A” metal plating is removed from the anode plating surface. In one aspect, in an initial charging of the battery, a permanent solid electrolyte interphase (SEI) layer is formed overlying the anode plating surface. In subsequent charging and discharging cycles, the permanent SEI layer is maintained overlying the anode plating surface.

Abstract: A transition metal hexacyanometallate (TMHCM)-conductive polymer (CP) composite electrode is provided. The battery electrode is made up of a current collector and a transition metal hexacyanometallate-conductive polymer composite overlying the current collector. The transition metal hexacyanometallate-conductive polymer includes a AXM1YM2Z(CN)N.MH2O material, where A may be alkali metal ions, alkaline earth metal ions, ammonium ions, or combinations thereof, and M1 and M2 are transition metal ions. The transition metal hexacyanometallate-conductive polymer composite also includes a conductive polymer material. In one aspect, the conductive polymer material is polyaniline (PANI) or polypyrrole (Ppy). Also presented herein are methods for the fabrication of a TMHCM-CP composite.

Abstract: A method is provided for synthesizing a metal-doped transition metal hexacyanoferrate (TMHCF) battery electrode. The method prepares a first solution of AxFe(CN)6 and Fe(CN)6, where A cations may be alkali or alkaline-earth cations. The method adds the first solution to a second solution containing M-ions and M?-ions. M is a transition metal, and M? is a metal dopant. Subsequent to stirring, the mixture is precipitated to form AxMcM?dFez(CN)n.mH2O particles. The AxMcM?dFez(CN)n.mH2O particles have a framework and interstitial spaces in the framework, where M and M? occupy positions in the framework. Alternatively, the method prepares AaA?bMyFez(CN)n.mH2O particles. A and A? occupy interstitial spaces in the AaA?bMyFez(CN)n.mH2O particle framework. A metal-doped TMHCF electrode is also provided.

Abstract: A structure of intimately contacting carbon-hexacyanometallate is provided for forming a metal-ion battery electrode. Several methods are provided for forming the carbon-hexacyanometallate intimate contact. These methods include (1) adding conducting carbon during the synthesis of hexacyanometallate and forming the carbon-hexacyanometallate powder prior to forming the paste for electrode printing; (2) coating with conducting carbon after hexacyanometallate powder formation and prior to forming the paste for electrode printing; and (3) coating a layer of conducting carbon over the hexacyanometallate electrode.

Abstract: A method is provided for synthesizing iron hexacyanoferrate (FeHCF). The method forms a first solution of a ferrocyanide source [A4Fe(CN)6.PH2O] material dissolved in a first solvent, where “A” is an alkali metal ion. A second solution is formed of a Fe(II) source dissolved in a second solvent. A reducing agent is added and, optionally, an alkali metal salt. The first and second solutions may be purged with an inert gas. The second solution is combined with the first solution to form a third solution in a low oxygen environment. The third solution is agitated in a low oxygen environment, and AX+1Fe2(CN)6.ZH2O is formed, where X is in the range of 0 to 1. The method isolates the AX+1Fe2(CN)6.ZH2O from the third solution, and dries the AX+1Fe2(CN)6.ZH2O under vacuum at a temperature greater than 60 degrees C.

Abstract: An air cathode battery is provided that uses a zinc slurry anode with carbon additives. The battery is made from an air cathode and a zinc slurry anode. The zinc slurry anode includes zinc particles, an alkaline electrolyte, with a complexing agent and carbon additives in the alkaline electrolyte. A water permeable ion-exchange membrane and electrolyte chamber separate the zinc slurry from the air cathode. The carbon additives may, for example, be graphite, carbon fiber, carbon black, or carbon nanoparticles. The proportion of carbon additives to zinc is in the range of 2.5 to 10% by weight. The proportion of alkaline electrolyte in the zinc slurry is in the range of 50 to 80% by volume.

Abstract: A method is provided for fabricating a transition metal hexacyanometallate (TMHCM) electrode with a water-soluble binder. The method initially forms an electrode mix slurry comprising TMHCF and a water-soluble binder. The electrode mix slurry is applied to a current collector, and then dehydrated to form an electrode. The electrode mix slurry may additionally comprise a carbon additive such as carbon black, carbon fiber, carbon nanotubes, graphite, or graphene. The electrode is typically formed with TMHCM greater than 50%, by weight, as compared to a combined weight of the TMHCM, carbon additive, and binder. Also provided are a TMHCM electrode made with a water-soluble binder and a battery having a TMHCM cathode that is made with a water-soluble binder.

Abstract: Methods are presented for synthesizing metal cyanometallate (MCM). A first method provides a first solution of AXM2Y(CN)Z, to which a second solution including M1 is dropwise added. As a result, a precipitate is formed of ANM1PM2Q(CN)R·FH2O, where N is in the range of 1 to 4. A second method for synthesizing MCM provides a first solution of M2C(CN)B, which is dropwise added to a second solution including M1. As a result, a precipitate is formed of M1[M2S(CN)G]1/T·DH2O, where S/T is greater than or equal to 0.8. Low vacancy MCM materials are also presented.

Abstract: A method is provided for forming a rechargeable metal-ion battery with a non-aqueous hybrid ion electrolyte. The method provides a transition metal hexacyanometallate (TMHCM) cathode (AXM1YM2Z(CN)N.MH2O), where “A” is from a first group of metals, and M1 and M2 are transition metals. The electrolyte includes a first type of cation from the first group of metals, different than “A”. The method connects the cathode and anode to external circuitry to perform initial charge/discharge operations. As a result, a hybrid ion electrolyte is formed including the first type of cation and “A” cations. Subsequently, cations are inserted into the anode during charging, which alternatively may be only “A” cations, only the first type of cation, or both the “A” cations and the first type of cation. Only “A” cations, only the first type, or both “A” and the first type of cation are inserted into the TMHCM during discharge.

Abstract: A method is provided for charging a supercapacitor. The method initially provides a supercapacitor with a metal cyanometallate (MCM) particle anode, an electrolyte including a salt (DB) made up of cations (D+) anions (B?), and a cathode including carbonaceous materials (?). The method connects an external charging device between the anode and cathode, and the charging device supplies electrons to the anode and accepting electrons from the cathode. In response to the charging device, cations are inserted into the anode while anions are absorbed on the surface of the cathode. A supercapacitor device is also presented.

Abstract: A reactive separator is provided for a metal-ion battery. The reactive separator is made up of a reactive layer that is chemically reactive to alkali or alkaline earth metals, and has a first side and a second side. A first non-reactive layer, chemically non-reactive with alkali or alkaline earth metals, is adjacent to the reactive layer first side. A second non-reactive layer, also chemically non-reactive with alkali or alkaline earth metals, is adjacent to the reactive layer second side. More explicitly, the first and second non-reactive layers are defined as having less than 5 percent by weight (wt %) of materials able to participate in electrochemical reactions with alkali or alkaline earth metals. The reactive layer may be formed as a porous membrane embedded with reactive components, where the porous membrane is carbon or a porous polymer. Alternatively, the reactive layer is formed as a polymer gel embedded with reactive components.

Abstract: A method is provided for fabricating a battery using an anode preloaded with consumable metals. The method forms an ion-permeable membrane immersed in an electrolyte. A preloaded anode is immersed in the electrolyte, comprising MeaX, where X is a material such as carbon, metal capable of being alloyed with Me, intercalation oxides, electrochemically active organic compounds, and combinations of the above-listed materials. Me is a metal such as alkali metals, alkaline earth metals, and combinations of the above-listed metals. A cathode is also immersed in the electrolyte and separated from the preloaded anode by the ion-permeable membrane. The cathode comprises M1YM2Z(CN)N.MH2O. After a plurality of initial charge and discharge operations are preformed, an anode is formed comprising MebX overlying the current collector in a battery discharge state, where 0?b<a.

Abstract: A method is presented for fabricating an anode preloaded with consumable metals. The method provides a material (X), which may be one of the following materials: carbon, metals able to be electrochemically alloyed with a metal (Me), intercalation oxides, electrochemically active organic compounds, and combinations of the above-listed materials. The method loads the metal (Me) into the material (X). Typically, Me is an alkali metal, alkaline earth metal, or a combination of the two. As a result, the method forms a preloaded anode comprising Me/X for use in a battery comprising a M1YM2Z(CN)N·MH2O cathode, where M1 and M2 are transition metals. The method loads the metal (Me) into the material (X) using physical (mechanical) mixing, a chemical reaction, or an electrochemical reaction. Also provided is preloaded anode, preloaded with consumable metals.

Abstract: A method is provided for forming a sodium-containing particle electrolyte structure. The method provides sodium-containing particles (e.g., NASICON), dispersed in a liquid phase polymer, to form a polymer film with sodium-containing particles distributed in the polymer film. The liquid phase polymer is a result of dissolving the polymer in a solvent or melting the polymer in an extrusion process. In one aspect, the method forms a plurality of polymer film layers, where each polymer film layer includes sodium-containing particles. For example, the plurality of polymer film layers may form a stack having a top layer and a bottom layer, where with percentage of sodium-containing particles in the polymer film layers increasing from the bottom layer to the top layer. In another aspect, the sodium-containing particles are coated with a dopant. A sodium-containing particle electrolyte structure and a battery made using the sodium-containing particle electrolyte structure are also presented.

Abstract: A method is provided for forming a metal battery electrode with a pyrolyzed coating. The method provides a metallorganic compound of metal (Me) and materials such as carbon (C), sulfur (S), oxygen (O), and combinations of the above-listed materials, expressed as MeXCYNZSXXOYY, where Me is a metal such as tin (Sn), antimony (Sb), or lead (Pb), or a metal alloy. The method heats the metallorganic compound, and as a result of the heating, decomposes materials in the metallorganic compound. In one aspect, decomposing the materials in the metallorganic compound includes forming a chemical reaction between the Me particles and the materials. An electrode is formed of Me particles coated by the materials. In another aspect, the Me particles coated with a material such as a carbide, a nitride, a sulfide, or combinations of the above-listed materials.

Abstract: A mechanism is presented for shielding a cathode in a metal cyanometallate battery. A battery is provided with an anode, a cathode, an electrolyte, and an ion-permeable membrane separating the anode from the cathode. The cathode is made up of a plurality of metal cyanometallate layers overlying the current collector. At least one of the metal cyanometallate layers is an active layer formed from an active material AXM1YM2Z(CN)N.MH2O, where “A” is an alkali metal, alkaline earth metal, or combination thereof. At least one of the metal cyanometallate layers is a shield layer comprising less than 50 percent by weight (wt %) active material. In response to applying an external voltage potential between the cathode and the anode, the method charges the battery. Upon discharge, the shield layer blocks metal particles from contacting active layers. Simultaneously, the shield layer transports metal ions from the electrolyte to the active layers.

Abstract: A method is provided for fabricating a cyanometallate cathode battery. The method provides a cathode of AXM1YM2Z(CN)N.MH2O, where “A” is selected from a first group of metals, and where M1 and M2 are transition metals. The method provides an anode and a metal ion-permeable membrane separating the anode from the cathode. A third electrode is also provided including “B” metal ions selected from the first group of metals. Typically, the first group of metals includes alkali and alkaline metals. The method intercalates “B” metal ions from the third electrode to the anode, the cathode, or both the anode and cathode to form a completely fabricated battery. In one aspect, a solid electrolyte interface (SEI) layer including the “B” metal ions overlies a surface of the anode, the cathode, or both the anode and cathode. A cyanometallate cathode battery is also provided.

Abstract: An alkali/oxidant battery is provided with an associated method of creating battery capacity. The battery is made from an anode including a reduced first alkali metal such as lithium (Li), sodium (Na), and potassium (K), when the battery is charged. The battery's catholyte includes an element, in the battery charged state, such as nickel oxyhydroxide (NiOOH), magnesium(IV) (oxide Mn(4+)O2), or iron(III) oxyhydroxide (Fe(3+)(OH)3), with the alkali metal hydroxide. An alkali metal ion permeable separator is interposed between the anolyte and the catholyte. For example, if the catholyte includes nickel(II) hydroxide (Ni(OH)2) in a battery discharged state, then it includes NiOOH in a battery charged state. To continue the example, the anolyte may include dissolved lithium ions (Li+) in a discharged state, with solid phase reduced Li formed on the anode in the battery charged state.

Abstract: A method is provided for synthesizing sodium iron(II)-hexacyanoferrate(II). A Fe(CN)6 material is mixed with the first solution and either an anti-oxidant or a reducing agent. The Fe(CN)6 material may be either ferrocyanide ([Fe(CN)6]4?) or ferricyanide ([Fe(CN)6]3?). As a result, sodium iron(II)-hexacyanoferrate(II) (Na1+XFe[Fe(CN)6]Z.MH2O is formed, where X is less than or equal to 1, and where M is in a range between 0 and 7. In one aspect, the first solution including includes A ions, such as alkali metal ions, alkaline earth metal ions, or combinations thereof, resulting in the formation of Na1+XAYFe[Fe(CN)6]Z.MH2O, where Y is less than or equal to 1. Also provided are a Na1+XFe[Fe(CN)6]Z.MH2O battery and Na1+XFe[Fe(CN)6]Z.MH2O battery electrode.