Method of manufacturing nickel zinc batteries

Abstract

Methods of manufacturing a rechargeable power cell are described. Methods include providing a slurry or paste of negative electrode materials having low toxicity and including dispersants to prevent the agglomeration of particles that may adversely affect the performance of power cells. The methods utilize semi-permeable sheets to separate the electrodes and minimize formation of dendrites; and further provide electrode specific electrolyte to achieve efficient electrochemistry and to further discourage dendritic growth in the cell. The negative electrode materials may be comprised of zinc and zinc compounds. Zinc and zinc compounds are notably less toxic than the cadmium used in NiCad batteries. The described methods may utilize some production techniques employed in existing NiCad production lines. Thus, the methods described will find particular use in an already well-defined and mature manufacturing base.

1 - 22 . (canceled) 
     
     
         23 . A rechargeable power cell comprising:
 a zinc negative electrode material applied to an anode carrier sheet having first and second opposing and substantially planar surfaces such that a first electrode is formed, wherein the negative electrode material includes a PTFE binder and little or no other organic dispersant;   a nickel positive electrode material applied to a cathode carrier sheet having first and second opposing and substantially planar surfaces such that a second electrode is formed;   a first semi-permeable dielectric sheet disposed along the first planar surface of the first electrode, a second semi-permeable dielectric sheet along the second planar surface of the first electrode, a third semi-permeable dielectric sheet along the first planar surface of the second electrode, and a fourth semi-permeable dielectric sheet along the second planar surface of the second electrode such that the first electrode and the second electrode are separated by only two semi-permeable dielectric sheets and rolled such that a cell assembly is formed;   a first terminal attached with a first end of the cell assembly such that the first electrode is in electrical communication only with the first terminal;   a second terminal attached with a second end of the cell assembly such that the second electrode is in electrical communication only with the second terminal;   a substantially cylindrical retaining vessel;   an electrolyte solution comprising fluoride, and hydroxide; and   a plurality of sealing terminals disposed at both ends of the retaining vessel such that the electrolyte and the cell assembly is substantially isolated from the environment.   
     
     
         24 . The rechargeable power cell of  claim 23  wherein the plurality of sealing terminals comprise a top terminal and a bottom terminal. 
     
     
         25 . The rechargeable power cell of  claim 24  wherein the top terminal is the positive terminal and the bottom terminal is the negative terminal. 
     
     
         26 . The rechargeable power cell of  claim 24  wherein the top terminal is the negative terminal and the bottom terminal is the positive terminal. 
     
     
         27 . The rechargeable power cell of  claim 26 , wherein the bottom terminal comprises the substantially cylindrical retaining vessel.