Provided is a continuous process for preparing a high quality and high performance nickel-iron battery comprising an iron electrode. The process comprises preparing a formulation comprising an iron active material and a binder and coating a continuous substrate material on a least one side with the formulation. The coated continuous substrate material is dried, compacted and blanked. A tab is then attached to the electrode.

The present invention provides one with a battery having an iron anode, e.g., a Ni—Fe battery, having improved performance characteristics. The battery uses a particular electrolyte and/or battery separator. The resulting characteristics of efficiency, charge retention and cycle life are much improved over such batteries in the prior art.

Provided is a process for preparing an electrode comprising an iron active material. The process comprises first fabricating an electrode comprising an iron active material, and then treating the surface of the electrode with water to thereby create an oxidized surface. The resulting iron electrode is preconditioned prior to any charge-discharge cycle to have the assessable surface of the iron active material in the same oxidation state as in discharged iron negative electrodes active material.

Provided is a negative electrode active material for a battery, the negative electrode active material comprising an iron compound, the iron compound containing a salt of a polyoxygen anion with iron, wherein the polyoxygen anion has a first atom and an oxygen atom, the first atom is at least one type of atom selected from atoms belonging to Group 4, Group 5, Group 6, Group 13, and Group 14 in the periodic table of elements, and a molar ratio of the oxygen atom to the first atom in the polyoxygen anion is more than 1.

Systems, methods, and devices of various aspects include using tin, antimony, and/or indium as an additive to an electrolyte and/or electrode in an electrochemical system, such as a battery, having an iron-based anode. In some aspects, the addition of tin, antimony, and/or indium may improve cycling of the iron-based anode. Systems, methods, and devices of various aspects include using high hydroxide concentration electrolyte in an electrochemical system, such as a battery. In some aspects, a high hydroxide concentration electrolyte may increase the stored amount of charge stored in the cell (i.e., the capacity of the battery material) and/or decrease the overpotential (i.e., increase the voltage) of the battery.

A green secondary electrode includes a conductive substrate, active material and material additives in direct contact with the conductive substrate, and a combination of vinyl acetate-ethylene and methylcellulose-based additive binding the conductive substrate, active materials, and material additives together. The green secondary electrode may be a positive electrode or a negative electrode.

Systems and methods of the various embodiments may provide porous materials for electrodes of electrochemical energy storage systems.

Novel pulsed aluminum batteries (PAlBs), including power output regulated systems, have been developed. PAlBs comprise an aluminum anode, a cathode, and a complex electrolyte containing bases, facilitating and stabilizing agents, and may contain internal oxidizers. The aluminum anode comprises technical grade or recycled aluminum. The cathode may comprise copper, nickel, or platinum. Bases may comprise sodium or potassium hydroxide. Facilitating and stabilizing agents may comprise sodium and lithium chlorides or sulfates. Internal oxidizers may comprise sodium hypochlorite. Frequency of electric pulses in novel PAlBs can be controlled by electric or chemical means. PAlBs can be used as components of backup power systems, in unmanned aerial vehicles (UAVs), and in autonomous self-powered electrochemical computing systems and sensors.

An iron-zinc battery includes a positive electrode containing iron oxyhydroxide, a negative electrode containing zinc, and an electrolyte disposed between the positive electrode and the negative electrode.

The present disclosure relates to rechargeable electrochemical battery cells (molten air batteries). The cells use air and a molten electrolyte, are quasi-reversible (rechargeable) and have the capacity for multiple electrons stored per molecule and have high intrinsic electric energy storage capacities. The present disclosure also relates to the use of such in a range of electronic, transportation and power generation devices, such as greenhouse gas reduction applications, electric car batteries and increased capacity energy storage systems for the electric grid.