A method for manufacturing zinc negative electrodes includes mixing a powder including zinc with polytetrafluoroethylene to form a homogenous blend, injecting a lubricant into the homogenous blend to form a dough, kneading the dough to form a fibrillated dough, and extruding the fibrillated dough through a die to form a ribbon. The method also includes calendering the ribbon to a target thickness to form a plaque, drying the plaque to form an active material sheet, laminating portions of the active material sheet to a current collector substrate to form an electrode blank, and sectioning the electrode blank into zinc negative electrodes.

Zinc electrolytic manganese dioxide (EMD) batteries including a high performing flexible chitosan-based gel electrolyte with poly-vinyl alcohol (PVA) and potassium hydroxide (KOH) additives were prepared. The Zn-EMD batteries were constructed using an optimized assembly technique employed to achieve good interfacial contact between the layers. Attaining energy densities between 150-250 Wh/kg (w.r.t cathode mass) is possible for these batteries, encouraging their use in wearable or flexible electronics. Using the chitosan-based gel electrolyte and limited voltage window testing, the prepared Zn-EMD alkaline batteries are among the best reported polymer-based alkaline electrolyte Zn rechargeable batteries.

The invention is directed towards a battery. The battery includes a cathode, an anode, a separator between the cathode and the anode, and an electrolyte. The cathode includes a conductive additive and an electrochemically active cathode material. The electrochemically active cathode material includes a beta-delithiated layered nickel oxide. The beta-delithiated layered nickel oxide has a chemical formula. The chemical formula is Li.sub.xA.sub.yNi.sub.1+a−zM.sub.zO.sub.2.nH.sub.2O where x is from about 0.02 to about 0.20; y is from about 0.03 to about 0.20; a is from about 0 to about 0.2; z is from about 0 to about 0.2; and n is from about 0 to about 1. Within the chemical formula, A is an alkali metal. The alkali metal includes potassium, rubidium, cesium, and any combination thereof. Within the chemical formula, M comprises an alkaline earth metal, a transition metal, a non-transition metal, and any combination thereof. The anode includes an electrochemically active anode material. The electrochemically active anode material includes zinc, zinc alloy, and any combination thereof.

Provided herein are novel organic sulfonic acid or sulfonate zinc-battery electrolyte additive chemicals with surprising advantageous properties such as, but not limited to, stability and the ability to facilitate zinc plating while limiting the formation of zinc dendrites.

The invention is directed towards an electrochemically active cathode material for a battery. The electrochemically active cathode material includes a non-stoichiometric beta-delithiated layered nickel oxide. The non-stoichiometric beta-delithiated layered nickel oxide has a chemical formula. The chemical formula is L.sub.ixA.sub.yNi.sub.1+a−zM.sub.zO.sub.2.Math.nH.sub.2O where x is from about 0.02 to about 0.20; y is from about 0.03 to about 0.20; a is from about 0.02 to about 0.2; z is from about 0 to about 0.2; and n is from about 0 to about 1. Within the chemical formula, A is an alkali metal. The alkali metal includes potassium, rubidium, cesium, and any combination thereof. Within the chemical formula, M comprises an alkaline earth metal, a transition metal, a non-transition metal, and any combination thereof.

A method for manufacturing a composite electrode for a metal-air electrochemical cell with a liquid electrolyte of basic pH. A liquid solution comprising a fluoropolymer suspended in a solvent is synthesized, then deposited on the outer surface of a porous structure forming an air electrode. The fluoropolymer comprises SO.sub.2N groups suitable for conducting hydroxyl ions and is capable of forming a membrane impermeable to at least the liquid electrolyte of basic pH. When the liquid solution is applied to the porous structure, the solvent flows through the porous structure and the fluoropolymer is deposited by aggregating into a layer on the outer surface of the porous structure.

Rechargeable batteries and corresponding methods are provided, in which zinc dendrite growth to a compartment between a zinc-based anode and a separator of a rechargeable battery is limited, by preventing zincate anions from diffusing outside of the compartment. Separators limiting dendrite growth may comprise ion-selective membrane(s) configured to be permeable to charge transfer cations of the alkaline electrolyte and impermeable to hydrated zincate anions. The membrane(s) may be reinforced and/or support internal compartment(s) with electrolyte lacking zincate ions. More generally, separators are provided, which are permeable to charge transfer ions but impermeable to metal ions, and limit the latter to the anode compartment in which the metal ions may be deposited in a manner that does not form dendrites which can compromise the structural and functional integrity of the battery cell.

The invention is directed towards an electrochemically active cathode material. The electrochemically active cathode includes beta-delithiated layered nickel oxide and an electrochemically active cathode material selected from the group consisting of manganese oxide, manganese dioxide, electrolytic manganese dioxide (EMD), chemical manganese dioxide (CMD), high power electrolytic manganese dioxide (HP EMD), lambda manganese dioxide, gamma manganese dioxide, beta manganese dioxide, and mixtures thereof. The beta-delithiated layered nickel oxide has an X-ray diffraction pattern. The X-ray diffraction pattern of the beta-delithiated layered nickel oxide includes a first peak from about 14.9°2θ to about 16.0°2θ; a second peak from about 21.3°2θ to about 22.7°2θ; a third peak from about 37.1°2θ to about 37.4°2θ; a fourth peak from about 43.2°2θ to about 44.0°2θ; a fifth peak from about 59.6°2θ to about 60.6°2θ; and a sixth peak from about 65.4°2θ to about 65.9°2θ.

A method of fabricating and using a zinc negative electrode and systems thereof are described. A zinc electroplated electrode including a layer of zinc metal bonded to a surface of an electrically conductive current collector is fabricated by an electroplating process using a zinc electroplating system. The zinc electroplating system includes: a zinc metal anode, a cathode including the current collector for plating zinc thereon, and an electrolyte bath comprising zinc ions. The electroplating process bonds the zinc metal to the surface of the current collector to create the electroplated zinc electrode. The electroplated zinc electrode is used as a negative electrode in a zinc metal cell. The zinc metal cell may be a primary cell or a secondary cell.

A zinc-air battery cell assembly comprising: a layer of anode material; one or more layers of cathode material; a separator directly between and engaging both the layer of anode material and the layer of cathode material that acts as both an electronic insulator and an ion conductive path between the layer of anode material and the layer of cathode material; and a diffusion member directly engaging the layer of cathode material.