Zaf Energy Systems, Incorporated

Michael J Gordon

Shiloh J Williams

Adam Weisenstein

Allen Charkey

Andrew F Souder, Ii

Eivind Listerud

Melissa D McIntyre

Randy Moore

Michael T Shireman

Hannah S Smith

An aqueous battery system includes an electrode assembly, a recombination device, and a controller. The recombination device has a catalyst that combines hydrogen and oxygen produced by the electrode assembly to form water and generate heat via exothermic reaction. The controller, responsive to a detected temperature or change in temperature associated with the recombination device due to the heat, changes power supplied to the electrode assembly.

Battery state indicator based on recombination device feedback

A method for manufacturing electrodes includes mixing a powder 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 outputting segments of the fibrillated dough. The method also includes processing the segments into a continuous plaque, drying the continuous 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 electrodes.

Electrode manufacturing

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.

An electrochemical component has a green secondary electrode including a conductive substrate, homogeneous pre-synthesized calcium zincate in direct contact with the conductive substrate, and a combination of styrene-butadiene rubber and sintered polytetrafluoroethylene binding the conductive substrate and calcium zincate together.

Secondary electrode including styrene-butadiene rubber

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 such that the current collector substrate is sandwiched between the portions to form an electrode blank, and sectioning the electrode blank into zinc negative electrodes.

Zinc electrode manufacturing

Monobloc batteries include compartments containing cells. Terminals extend into the compartments and are electrically connected with the cells via tabs. The tabs are folded to form bent stacks and include openings in partial registration with each other. The terminals extend through the openings and are secured to the tabs. The terminals are off-center relative to the compartments to preserve space for the bent stacks.

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Joplin, MO, United States of America

Michael J Gordon