Alkaline electrochemical cells are provided, wherein a long-chain surfactant is included in at least one component of the cell in order to delay anode shutdown. Methods for preparing such cells are also provided.

An anode composition, an alkali battery, a method of making a battery anode, and a method of making a battery, wherein the anode comprises a zinc or zinc alloy and a surfactant of formula (I):

##STR00001## wherein R.sub.1, R.sub.2, and R.sub.3 are each individually selected from hydrogen, C.sub.1-C.sub.12 alkyl, and aryl; y is null or 1, x is an integer from 2 to 30, n is an integer from 2 to 6, and M is hydrogen or an alkali metal; provided that: when two of R.sub.1, R.sub.2, and R.sub.3 are hydrogen, at least one of R.sub.1, R.sub.2, and R.sub.3 is a C.sub.4-C.sub.12 alkyl or aryl; or, when each of R.sub.1, R.sub.2, and R.sub.3 are alkyl or aryl, at least one of R.sub.1, R.sub.2, and R.sub.3 comprises a C.sub.2-C.sub.12 alkyl or aryl; or when R.sub.1 is hydrogen, then (a) each of R.sub.2 and R.sub.3 comprises a C.sub.2-C.sub.12 alkyl or aryl or (b) at least one of R.sub.2 and R.sub.3 comprises a C.sub.3-C.sub.12 alkyl or aryl.

An iron electrode and a method of manufacturing an iron electrode for use in an iron-based rechargeable battery are disclosed. In one embodiment, the iron electrode includes carbonyl iron powder and one of a metal sulfide additive or metal oxide additive selected from the group of metals consisting of bismuth, lead, mercury, indium, gallium, and tin for suppressing hydrogen evolution at the iron electrode during charging of the iron-based rechargeable battery. An iron-air rechargeable battery including an iron electrode comprising carbonyl iron is also disclosed, as is an iron-air battery wherein at least one of the iron electrode and the electrolyte includes an organosulfur additive.

An iron electrode and a method of manufacturing an iron electrode for use in an iron-based rechargeable battery are disclosed. In one embodiment, the iron electrode includes carbonyl iron powder and one of a metal sulfide additive or metal oxide additive selected from the group of metals consisting of bismuth, lead, mercury, indium, gallium, and tin for suppressing hydrogen evolution at the iron electrode during charging of the iron-based rechargeable battery. An iron-air rechargeable battery including an iron electrode comprising carbonyl iron is also disclosed, as is an iron-air battery wherein at least one of the iron electrode and the electrolyte includes an organosulfur additive.

An alkaline dry cell includes a positive electrode, a negative electrode, and an alkaline electrolyte solution. The negative electrode includes a terephthalic acid compound and a negative electrode active material containing zinc. The terephthalic acid compound is terephthalic acid having an electron-withdrawing substituent or a salt thereof. The electron-withdrawing substituent is, for example, at least one selected from the group consisting of Br, F, and Cl. The terephthalic acid compound preferably includes terephthalic acid having one electron-withdrawing substituent or a salt thereof.

An alkaline dry cell includes a positive electrode, a negative electrode, and an alkaline electrolyte solution. The negative electrode includes a terephthalic acid compound and a negative electrode active material containing zinc. The terephthalic acid compound is terephthalic acid having an electron-withdrawing substituent or a salt thereof. The electron-withdrawing substituent is, for example, at least one selected from the group consisting of Br, F, and Cl. The terephthalic acid compound preferably includes terephthalic acid having one electron-withdrawing substituent or a salt thereof.

An alkaline electrochemical cell includes a cathode, an anode which includes an anode active material, and a non-conductive separator disposed between the cathode and the anode, wherein from about 20% to about 50% by weight of the anode active material relative to a total amount of anode active material has a particle size of less than about 75 m, and wherein the separator includes a unitary, cylindrical configuration having an open end, a side wall, and integrally formed closed end disposed distally to the open end.

A method of manufacturing a zinc-manganese dioxide cell includes applying a first electrical conductor to an electrically non-conductive substrate and applying a second electrical conductor to the electrically non-conductive substrate. The method further includes applying a layer-shaped negative electrode directly onto the first electrical conductor, applying a layer-shaped positive electrode directly onto the second electrical conductor, providing a layer-shaped separator, applying at least one electrolyte layer to the layer-shaped negative electrode and/or to the layer-shaped positive electrode and/or to the layer-shaped separator, and forming a stack of layers with the sequence negative electrode/separator/positive electrode. The negative electrode is formed of a paste comprising zinc powder (mercury free), electrode binder, and solvent and/or dispersant. The positive electrode is formed of a paste comprising manganese dioxide, conductive material for improving electrical conductivity, electrode binder, and solvent and/or dispersant.

A method of manufacturing a zinc-manganese dioxide cell includes applying a first electrical conductor to an electrically non-conductive substrate and applying a second electrical conductor to the electrically non-conductive substrate. The method further includes applying a layer-shaped negative electrode directly onto the first electrical conductor, applying a layer-shaped positive electrode directly onto the second electrical conductor, providing a layer-shaped separator, applying at least one electrolyte layer to the layer-shaped negative electrode and/or to the layer-shaped positive electrode and/or to the layer-shaped separator, and forming a stack of layers with the sequence negative electrode/separator/positive electrode. The negative electrode is formed of a paste comprising zinc powder (mercury free), electrode binder, and solvent and/or dispersant. The positive electrode is formed of a paste comprising manganese dioxide, conductive material for improving electrical conductivity, electrode binder, and solvent and/or dispersant.

An anaerobic aluminum-water electrochemical cell is provided. The electrochemical cell includes: a plurality of electrode stacks, each electrode stack comprising an aluminum or aluminum alloy anode, and at least one cathode configured to be electrically coupled to the anode and having a surface characterized by an electrochemical roughness factor of at least 5 and a mean pore diameter of at least 50 m; one or more physical separators between each electrode stack adjacent to the cathode; a housing configured to hold the electrode stacks, an electrolyte, and the physical separators; and a water injection port, in the housing, configured to introduce water into the housing.