Pouched metal-air battery cells

Abstract

A metal air battery cell has a sealed pouch defined by a metallocene film and a gas and liquid impermeable flexible layer, and an electrochemical cell contained within the pouch. The metallocene film and gas and liquid impermeable flexible layer are sealed to each other and around the electrochemical cell.

What is claimed is: 
     
         1 . A metal air battery cell comprising:
 an electrode assembly including an air electrode and a gas permeable hydrophobic flexible layer in contact with the air electrode;   a negative electrode;   a separator in contact with and disposed between the electrodes; and   a sealed pouch that envelops the electrode assembly and contains an electrolyte therein, wherein the pouch is defined by a metallocene film that is in contact with the electrodes and completely covers the gas permeable hydrophobic flexible layer such that the gas permeable hydrophobic flexible layer is between the metallocene film and air electrode.   
     
     
         2 . The metal air battery cell of  claim 1 , wherein the metallocene film is in contact with or adhered with the gas permeable hydrophobic flexible layer. 
     
     
         3 . The metal air battery cell of  claim 1  further comprising a terminal extending from and away at least one of the electrodes, and through the pouch such that the metallocene film is in contact with the terminal and sealed around the terminal. 
     
     
         4 . The metal air battery cell of  claim 1 , wherein the negative electrode includes zinc. 
     
     
         5 . The metal air battery cell of  claim 1 , wherein the gas permeable hydrophobic flexible layer includes a non-sintered polytetrafluoroethylene film. 
     
     
         6 . The metal air battery cell of  claim 1 , wherein the gas permeable hydrophobic flexible layer includes a carbon network. 
     
     
         7 . A metal air battery cell comprising:
 an electrode assembly including two air electrodes and two gas permeable hydrophobic flexible layers;   a negative electrode disposed between the air electrodes;   at least one separator in contact with and disposed between the air electrodes and negative electrode; and   a sealed pouch that envelops the electrode assembly and contains an electrolyte therein, wherein the pouch is defined by a metallocene film in contact with the air electrodes such that the metallocene film is in contact with and completely covers the two gas permeable hydrophobic flexible layers, and each of the gas permeable hydrophobic flexible layers is between the metallocene film and one of the air electrodes.   
     
     
         8 . The metal air battery cell of  claim 7 , wherein the metallocene film is in contact with or adhered with the gas permeable hydrophobic flexible layers. 
     
     
         9 . The metal air battery cell of  claim 7  further comprising a terminal extending from and away at least one of the electrodes, and through the pouch such that the metallocene film is in contact with the terminal and sealed around the terminal. 
     
     
         10 . The metal air battery cell of  claim 7 , wherein the negative electrode includes zinc. 
     
     
         11 . The metal air battery cell of  claim 7 , wherein each of the gas permeable hydrophobic flexible layers includes a non-sintered polytetrafluoroethylene film. 
     
     
         12 . The metal air battery cell of  claim 7 , wherein each of the gas permeable hydrophobic flexible layers includes a carbon network. 
     
     
         13 . A metal air battery cell comprising:
 a sealed pouch defined by a metallocene film and a gas and liquid impermeable flexible layer; and   an electrochemical cell contained within the pouch, wherein the metallocene film and gas and liquid impermeable flexible layer are sealed to each other and around the electrochemical cell.   
     
     
         14 . A metal air battery cell comprising:
 an electrode assembly including a tab;   an electrolyte in contact with the electrode assembly; and   a pouch sealed to and around the tab and configured to contain the electrode assembly and electrolyte therein such that the pouch is in direct contact with the electrode assembly and electrolyte, wherein the pouch is defined by a metallocene film.