Energy Technology Data Exchange (ETDEWEB)

This report summarizes the results of research conducted during the sixteen month continuation of a program to develop rechargeable zinc-air batteries for electric vehicles. The zinc-air technology under development incorporates a metal foam substrate for the zinc electrode, with flow of electrolyte through the foam during battery operation. In this ``soluble`` zinc electrode the zincate discharge product dissolves completely in the electrolyte stream. Cycle testing at Lawrence Berkeley Laboratory, where the electrode was invented, and at MATSI showed that this approach avoids the zinc electrode shape change phenomenon. Further, electrolyte flow has been shown to be necessary to achieve significant cycle life (> 25 cycles) in this open system. Without it, water loss through the oxygen electrode results in high-resistance failure of the cell. The Phase I program, which focused entirely on the zinc electrode, elucidated the conditions necessary to increase ...

Energy Technology Data Exchange (ETDEWEB)

Proof-of-principle experiments are reported for a new concept in electrically rechargeable zinc-air battery. The zinc electrode is a porous flow-thru type using a copper foam metal substrate with zinc deposition onto the foam metal from concentrated zincate electrolyte (as used in zinc-slurry type batteries). The bifunctional air electrode employs low-cost materials, being fabricated entirely from carbon-based precursors and small amounts of nickel and/or cobalt oxide. Corrosion measurements on the graphite materials in the air electrode indicate sufficient corrosion resistance for 8000 h life on charge. A prototype single cell was constructed having 1.5 Ah capacity producing 1.2 V discharge -2.0 charge at the three hour rate and has produced stable voltages for more than 150 cycles. Based on the 1.5 Ah prototype characteristics, design calculations for a 32 kWh battery project an energy density of about 110 Wh/kg, peak power density of 140 W/kg, electrical ...

Energy Technology Data Exchange (ETDEWEB)

A new type of zinc electrode is matched with new bifunctional air electrodes to produce a zinc-air battery of a novel design. The zinc electrode is a flow-thru type made from copper foam-metal. The air electrode uses corrosion resistant carbon black as a high area support for a highly dispersed spinel oxide electrocatalyst. The battery design employs flowing electrolyte, 12 M KOH saturated or supersaturated with zincate. Single cells as large as 200 cm{sup 2} (1/5 EV design scale) having a capacity of 20 AH have been tested with C/4--C/16 constant current cycling. More extensive and realistic life cycle testing was done with 2 Ah cells, including the Simplified Federal Urban Driving Schedule (SFUDS) cycle. This testing has confirmed that these cells can provide the necessary transient power response required for urban EV applications. The cells achieved an average of 72 SFUDS repetitions (7.2 hrs) per discharge cycle, more than twice the number with a sealed lead ...