Wall Mounted Zinc Batteries

Abstract

Rechargeable and replaceable zinc cartridges have been used as the components of nickel-zinc batteries. The battery life of a zinc battery is extended by periodic replacing of the zinc anodes at about 10% of the battery cost. Flat modules that include several cells interconnected with channels are used as basic elements of a flat battery. A home wall battery is produced by assembling the modules using rotational joints. The performance of the zinc current collectors is improved by deposition of Zn—Cu—Bi alloy. Zinc composition is formulated using additives of polyphenylenediamines and zirconium hollow fibers.

1 . A battery cell, other than metal-air battery, that includes a zinc anode with current collector, a cathode with current collector, and electrolyte wherein the zinc anode is rechargeable and replaceable 
     
     
         2 . A battery cell of  claim 1  wherein the cathode is nickel oxide-hydroxide 
     
     
         3 . Rechargeable and replaceable zinc anode of  claim 1  wherein the zinc anode is wrapped in a hermetically sealed separator 
     
     
         4 . Rechargeable and replaceable zinc anode of  claim 1  wherein the zinc anode includes zinc powder or dust with particle sizes in the interval 0.1 mkm-7 mkm 
     
     
         5 . Rechargeable and replaceable zinc anode of  claim 1  wherein the zinc anode includes polyaminodiphenylamine, or its derivative in concentration range 0.1%-7% 
     
     
         6 . Rechargeable and replaceable zinc anode of  claim 1  wherein the zinc anode includes current collector made of zinc, nickel, copper, bronze, stainless steel, lead, bismuth or their alloys covered with a layer of zinc-bismuth-copper alloy 
     
     
         7 . A current collector of a nickel-oxide hydroxide, an air reduction, an oxygen evolution electrodes wherein the current collector is made of low surface area material on one side, and large surface area material on the other side 
     
     
         8 . A current collector of  claim 7  wherein large surface area material is metal foam 
     
     
         9 . A current collector of  claim 7  wherein low surface area material is metal sheet, foil, mesh or expanded metal 
     
     
         10 . A battery module that includes a base, two walls, a cathode, as well as rechargeable and replaceable zinc anodes wherein the module is flat, and is internally connected with channels filled with electrolyte 
     
     
         11 . A battery module of  claim 10  wherein the module base is formed of two sheets with pockets for zinc electrodes 
     
     
         12 . A battery module of  claim 10  wherein the module includes walls made of nickel oxide-hydroxide cathodes 
     
     
         13 . A module of  claim 10  wherein the module includes walls made of air reduction and oxygen evolution electrodes 
     
     
         14 . A module of  claim 10  wherein the module is a hybrid of a battery and a supercapacitor 
     
     
         15 . A module of  claim 10  wherein the module is assembled by gluing 
     
     
         16 . A module of  claim 10  wherein the module case is made of “smart ABS” plastic formed by 3d printing or casting 
     
     
         17 . A module of  claim 10  wherein the module case is made of plastic, rubber, or ceramic filled with empty spheres or hollow fibers 
     
     
         18 . A module of  claim 10  wherein the module is split into elemental cells connected to each other with flexible tubes 
     
     
         19 . A module of  claim 10  wherein the module is split into elemental cells connected to each other with flexible tubes filled with electrolyte 
     
     
         20 . A home wall mounted battery wherein the battery is formed of flat modules that include rechargeable and replaceable zinc anodes, and is assembled using rotational joints 
     
     
         21 . A method of operation of batteries with replaceable and rechargeable zinc anodes wherein the anodes are replaced periodically after a long term interval 
     
     
         22 . A method of operation of batteries of  claim 21  wherein the zinc anodes are replaced with discharged zinc anodes when the cathodes are in the discharged state 
     
     
         23 . A method of operation of batteries of  claim 21  wherein the zinc anodes are replaced with charged zinc anodes when the cathodes are in the charged state 
     
     
         24 . A method of production of the battery module with rechargeable and replaceable zinc anodes wherein
 a) Two polymer sheets are milled to form the pockets for elemental cells   b) The channels are milled in one or the both sheets   c) The sheets are glued, welded to each other to form the base of the module   d) Nickel oxide-hydroxide cathodes and plastic sheets are glued to the base to form side walls   e) The replaceable and rechargeable zinc electrodes are placed in the pockets   f) The pockets are closed with rubber or plastic caps   g) The caps are sealed with a sealant   
     
     
         25 . The method of  claim 24  wherein at stage d) the air evolution and air reduction electrodes are glued to the module base 
     
     
         26 . A battery module of  claim 10  wherein the electrodes are connected using three position relays, and by default the module is in the discharge mode of operation 
     
     
         27 . A battery module of  claim 10  wherein the electrodes are connected using three position relays in such a way that the connection to the charger turns the relays to charging mode 
     
     
         28 . Rechargeable and replaceable zinc anode of  claim 1  wherein the zinc anode includes zirconia hollow fibers in the amount 0.1%-5% mass %