Battery

Abstract

We aim to reduce costs by solving the issues with existing flooded batteries. [Solution] A battery comprising: a plastic housing having an inner surface defining a chamber in which an electrolyte (104) is disposed; a conductive surface located within the chamber adjacent to the inner surface of the housing and configured to be electrically connected to the anode terminal of the battery; a permeable separator sheet (105) located within the housing and configured to electrically insulate the electrolyte from the conductive surface; a conductive rod (103) having a first end configured to be electrically connected to the cathode terminal (101C') of the battery and a second end configured to be electrically connected to the electrolyte; and an opening located in the housing that allows liquid to enter the chamber for interaction with the electrolyte by generating a potential difference between the conductive surface and the conductive rod, thereby making the electrolyte suitable for operation of the battery.

Description

[Technical Field]

[0001] The present invention relates to the field of reusable batteries, and in particular to batteries that are activated by the addition of a liquid such as water. [Background technology]

[0002] Conventional off-the-shelf type AA and AAA batteries tend to degrade in performance over time during storage, which can pose serious problems when reliable battery performance is critical, such as in emergency situations where batteries are required to power flashlights, radios, mobile phones, or other potentially life-saving electronic devices.

[0003] In an attempt to address this problem, water-activatable batteries have been developed that can be stored in a non-operating state (i.e., before the electrolyte powder mixture and water in the battery have been mixed to activate the electrolyte powder mixture) for relatively long periods of time without substantial loss in battery performance when the battery is subsequently activated by adding water.

[0004] However, existing water-activated batteries also have certain drawbacks, including the fact that the structure and material composition of such batteries are still considered by some to be overly complicated and more costly than may be necessary for mass production. Also, the structure of existing water-activated batteries is such that the accidental loss of battery components can render such batteries unusable, which is naturally undesirable, especially in emergency situations.

[0005] Furthermore, during battery manufacturing, problems tend to occur when filling the battery housing with electrolyte powder. Specifically, as the electrolyte is injected into the battery housing, the electrolyte powder tends to clog the delivery channels, requiring frequent cleaning of the delivery channels. This problem associated with tube clogging causes unacceptable delays and inefficiencies in battery manufacturing, impacting the overall cost of manufacturing. Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention seeks to alleviate at least one of the problems discussed above with respect to the prior art. [Means for solving the problem]

[0007] The present invention may include multiple generic forms. Embodiments of the present invention may include one or any combination of the various generic forms described herein.

[0008] In a first general aspect, the present invention provides a battery comprising: a plastic housing having an interior surface defining a chamber in which an electrolyte is disposed; a conductive surface located within the chamber adjacent the inner surface of the housing, the conductive surface being configured to be in electrical communication with the anode terminal of the battery; a permeable separator sheet located within the housing and configured to electrically insulate the electrolyte from the conductive surface; a conductive rod having a first end configured to electrically connect to a cathode terminal of the battery and a second end configured to electrically connect to an electrolyte; an opening disposed in the housing to allow ingress of liquid into the chamber for interaction with the electrolyte such that the electrolyte is suitable for operation of the battery by creating a potential difference between the conductive surface and the conductive bar; A battery comprising:

[0009] Preferably, the first and second parts are movable relative to one another by at least one of a sliding, rotating, pivoting, twisting, pulling and pushing action.

[0010] Typically, the first and second parts of the housing may comprise valve components of the housing to controllably admit liquid into the chamber.

[0011] Preferably, the housing may comprise a plastic material, more preferably, the plastic may comprise a recyclable plastic material.

[0012] Preferably, the conductive surface may comprise a conductive lining of the housing.

[0013] Preferably, the conductive surface may comprise a zinc material.

[0014] Preferably, the conductive surface may have at least one of an abatement, a slot, and a series of holes extending substantially along the longitudinal axis of the conductive surface.

[0015] Preferably, at least one of the relief, slot and series of holes may be formed as a cutout in the conductive surface.

[0016] Preferably, the anode terminal can be disposed in a first end portion of the housing, the first end portion including a combination of a plastic material and a metal material, and preferably, the plastic region can concentrically surround a core formed of a metal material.

[0017] Preferably, the present invention may include a spring positioned within the housing and configured to provide an electrical connection between the conductive surface of the housing and the anode terminal.

[0018] Preferably, the electrolyte may include substantially spherical particles having diameters in the range of approximately 0.2 mm to 0.8 mm.

[0019] Preferably, the electrolyte has a density of approximately 1.71 g / cm 3 ~1.75g / cm 3 The particles may include particles in the range of

[0020] Preferably, the particles can have a moisture content of approximately 3% or less.

[0021] In a second general aspect, the present invention provides a battery comprising: a housing having an interior surface defining a chamber within which an electrolyte is disposed; a conductive surface located within the chamber adjacent the inner surface of the housing, the conductive surface being configured to electrically connect with an anode terminal of the battery; a permeable separator sheet located within the housing and configured to electrically insulate the electrolyte from the conductive surface; a conductive rod having a first end configured to electrically connect to a cathode terminal of the battery and a second end configured to electrically connect to an electrolyte; an opening disposed in the housing to allow ingress of liquid into the chamber for interaction with the electrolyte such that the electrolyte is suitable for operation of the battery by creating a potential difference between the conductive surface and the conductive bar; Equipped with The conductive surface provides a battery having at least one of a relief, a slot, and a series of holes extending substantially along the longitudinal axis of the conductive surface.

[0022] Preferably, the plastic may comprise a recyclable plastic material.

[0023] Typically, the conductive surface may include a conductive lining of a housing.

[0024] Preferably, the conductive surface may comprise a zinc material.

[0025] Preferably, the conductive surface may have at least one of a relief, a slot and a series of holes extending substantially along the longitudinal axis of the conductive surface.

[0026] Preferably, at least one of the relief, slot and series of holes may be formed as a cutout in the conductive surface.

[0027] Preferably, the anode termination may be located at a first end portion of the housing, the first end portion comprising a combination of plastic and metal materials.

[0028] Preferably, the plastic region may concentrically surround a core formed of a metallic material.

[0029] Preferably, the present invention may include a spring positioned within the housing and configured to provide an electrical connection between the conductive surface of the housing and the anode terminal.

[0030] Preferably, the housing may comprise at least a first part and a second part movably mounted to one another, the first part and the second part being movable relative to one another between at least a first mounted position in which the opening is substantially blocked to prevent liquid from entering the housing through the opening, and a second mounted position in which the opening is substantially open to allow liquid to enter through the opening and contact the electrolyte in the chamber, generating a potential difference between the conductive surface and the conductive bar, thereby activating the battery.

[0031] Preferably, the first and second parts are movable relative to one another by at least one of a sliding, rotating, pivoting, twisting, pulling and pushing action.

[0032] Preferably, the first and second parts of the housing may comprise valve components of the housing to controllably admit liquid into the chamber.

[0033] Preferably, the electrolyte may include substantially spherical particles having diameters in the range of approximately 0.2 mm to 0.8 mm.

[0034] Preferably, the electrolyte has a density of approximately 1.71 g / cm 3 ~1.75g / cm 3 The particles may include particles in the range of

[0035] Preferably, the particles can have a moisture content of approximately 3% or less.

[0036] In a third general form, the present invention provides a battery comprising: a housing having an interior surface defining a chamber within which an electrolyte is disposed; a conductive surface located within the chamber adjacent the inner surface of the housing, the conductive surface being configured to electrically connect with an anode terminal of the battery; a permeable separator sheet located within the housing and configured to electrically insulate the electrolyte from the conductive surface; a conductive rod having a first end configured to electrically connect to a cathode terminal of the battery and a second end configured to electrically connect to an electrolyte; an opening disposed in the housing to allow ingress of liquid into the chamber for interaction with the electrolyte such that the electrolyte is suitable for operation of the battery by creating a potential difference between the conductive surface and the conductive bar; Equipped with an anode terminal disposed at a first end portion of the housing; The first end portion provides the battery including a combination of plastic and metal materials.

[0037] Preferably, the housing may comprise a plastic material, more preferably, the plastic may comprise a recyclable plastic material.

[0038] Typically, the conductive surface may include a conductive lining of a housing.

[0039] Preferably, the conductive surface may comprise a zinc material.

[0040] Preferably, at least one of the relief, slot and series of holes may be formed as a cutout in the conductive surface.

[0041] Preferably, the housing may comprise at least a first part and a second part movably mounted to one another, the first part and the second part being movable relative to one another between at least a first mounted position in which the opening is substantially blocked to prevent liquid from entering the housing through the opening, and a second mounted position in which the opening is substantially open to allow liquid to enter through the opening and contact the electrolyte in the chamber, generating a potential difference between the conductive surface and the conductive bar, thereby activating the battery.

[0042] Preferably, the first and second parts are movable relative to one another by at least one of a sliding, rotating, pivoting, twisting, pulling and pushing action.

[0043] Preferably, the first and second parts of the housing may comprise valve components of the housing to controllably admit liquid into the chamber.

[0044] Preferably, the anode termination may be located at a first end portion of the housing, the first end portion comprising a combination of plastic and metal materials.

[0045] Preferably, the plastic region may concentrically surround a core formed of a metallic material.

[0046] Preferably, the present invention may include a spring positioned within the housing and configured to provide an electrical connection between the conductive surface of the housing and the anode terminal.

[0047] Preferably, the electrolyte may include substantially spherical particles having diameters in the range of approximately 0.2 mm to 0.8 mm.

[0048] Preferably, the electrolyte has a density of approximately 1.71 g / cm 3 ~1.75g / cm 3 The particles may include particles in the range of

[0049] Preferably, the particles can have a moisture content of approximately 3% or less.

[0050] The present invention will be more fully understood from the following detailed description of preferred, but non-limiting, embodiments of the invention, taken in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0051] [Figure 1] 1 is a cross-sectional side view of a battery according to a first embodiment of the present invention. [Figure 2] FIG. 1 is an enlarged cross-sectional side view of a first end of a first embodiment battery, illustrating one way in which the first end portion can be movably attached to a cylindrical section of a housing to allow controllable ingress of water into the housing. [Figure 3] 10A-10C illustrate a conductive lining configured to line the interior surface of the housing in accordance with an embodiment of the present invention. [Figure 4] FIG. 1 shows a plate-shaped conductive lining before being rolled into a cylindrical shape. DETAILED DESCRIPTION OF THE INVENTION

[0052] Preferred embodiments of the present invention will now be described with reference to the accompanying Figures 1-4. The exemplary embodiments described herein include a battery that can be activated by controllably injecting a liquid into a chamber of the battery through an opening in the battery housing and contacting the electrolyte powder 104 therein. Such embodiments conform to the standard shape and size requirements of off-the-shelf AA and AAA batteries and can be suitably configured to provide an electrical output comparable to off-the-shelf AA and AAA batteries.

[0053] 1 shows a cross-sectional side view of a battery according to one embodiment of the present invention. The battery comprises housings 101A, 101B, 101C made from a biodegradable plastic material, each housing 101A, 101B, 101C including a cylindrical section 101A disposed between a first end portion 101B and a second end portion 101C attached to opposite ends of the cylindrical section 101A of the housing.

[0054] The first end portion 101B of the housing is movably attached to the cylindrical section 101A of the housing and is configured to be movable between at least a first attachment position that allows water to enter the housing through an opening disposed in the housing and a second attachment position that blocks water from entering the housing through the opening. When the first end portion 101B of the housing is positioned in either the first or second attachment position, it is configured not to be separated or detached from the cylindrical section 101A of the housing during normal use of the battery. In contrast, certain existing water-filled batteries include battery housings that include end caps that are removable or separable from the housing (e.g., can be unscrewed from the housing) to allow the housing to be filled with water through an opening in the end of the housing. However, the end caps of such existing water-filled batteries can be easily lost or misplaced once removed or detached from the housing. Therefore, such problems can be alleviated by embodiments of the present invention.

[0055] 2 illustrates an exemplary embodiment in which the housing first end portion 101B is rotatably mounted to the housing cylindrical section 101A. In this exemplary embodiment, the housing first end portion 101B includes a lip 202 extending around the periphery of the first end portion 101B such that, when the first end portion 101B is urged inwardly into the cylindrical section 101A during battery assembly, the lip 202 resiliently engages a corresponding recess 201 extending around the inner surface of the housing cylindrical section 101A. Receiving the resilient lip 202 within the recess 201 allows the first end portion 101B to rotate coaxially relative to the housing cylindrical section 101A between at least a first mounting position in which an opening 200C disposed in the first end portion 101B and an opening disposed in the housing cylindrical section 101A are aligned. When in this first mounting position, immersing the battery in water allows water to enter the housing through the aligned openings. However, when the first end portion 101B of the housing and the cylindrical section 101A of the housing are rotated to the second mounting position, the openings 200C in the first end portion 101B and the openings in the cylindrical section 101A of the housing are no longer aligned, and water is no longer able to enter the housing.

[0056] In alternative embodiments of the present invention, the housing first end portion 101B and the housing cylindrical section 101A may be movably attached relative to one another in other ways to controllably allow water to enter the housing without being removed or separated from one another during normal use of the battery. For example, the housing first end portion 101B and the housing cylindrical section 101A may be slidably attached to one another and movable relative to one another between various attachment positions to controllably allow water to enter the housing. In one such embodiment, pulling the housing first end portion 101B outward from the first end of the housing cylindrical section 101A to a first attachment position may align the openings in the first end portion 101B and the cylindrical section 101A, allowing water to enter the housing. Conversely, pushing the first end portion 101B inward from the housing first end may cause the openings to become out of alignment, thereby preventing water from entering the housing. Alternatively, the first end portion 101B of the housing may be hingedly attached to the cylindrical section 101A of the housing.

[0057] In still further embodiments, the first end portion 101B need not necessarily be movably attached to the cylindrical section 101A of the housing. Other portions of the housing may be movably attached relative to each other in other ways and configurations for controllably admitting water into the housing. By way of example, the first and second end portions 101B, 101C of the housing may be fixed to the first and second ends, respectively, of the cylindrical section 101A of the housing and may be configured to be completely immobile. Instead, an opening to the housing may be located at an intermediate position along the cylindrical section 101A, and the cylindrical section 101A may include first and second portions that are movably attached to allow water to controllably enter the housing through the opening. To simplify the manufacture and operation of embodiments of the present invention, a prefabricated type valve mechanism, e.g., a “twist-type valve,” of suitable shape and size may be incorporated into the battery housing to controllably admit water into the housing.

[0058] As shown in FIG. 2, the first end portion 101B of the housing forms the anode terminal 200A of the battery. Unlike certain other water-filled batteries, the first end portion 101B is not made entirely of metal, but rather is formed from a novel combination of biodegradable plastic and metal. The novel configuration of the first end portion 101B, including a combination of metal 200A and biodegradable plastic 200B in embodiments of the present invention, provides advantages over existing batteries in terms of reduced manufacturing costs (due to the use of less metal) and reduced overall battery weight. The metal material forms a core 200A that extends from one side of the first end portion to the other and is concentrically surrounded by plastic material 200B. When first end portion 101B is attached to cylindrical housing section 101A, plastic periphery 200B of first end portion 101B and the plastic material of cylindrical housing section 101A can be configured to deformably engage with one another to some extent, which may tend to provide a better airtight seal than certain existing water-filled batteries. That is, certain existing water-filled batteries with metal end caps and metal housings tend to provide a poorer seal due to metal-to-metal engagement. Even with the inclusion of an O-ring (which adds cost and complexity to such existing batteries), the airtight seal may not be as effective as in embodiments of the present invention.

[0059] The second end portion 101C is rigidly secured to the second end of the cylindrical section 101A, thereby forming an airtight seal between the second end portion 101C and the second end of the cylindrical section 101A of the housing. In certain embodiments, the second end portion 101C may be integrally molded with the cylindrical section 101A of the housing from a single piece of biodegradable plastic. A hole approximately 4 mm to 6 mm in diameter may be disposed in the center of the second end portion 101C, through which a conductive cathode terminal 101C' is configured to protrude. The cathode terminal 101C' in this embodiment includes a stainless steel cap 101C' that seats snugly within the hole to provide an airtight seal within the battery chamber. The carbon rod 103 extends inside the battery housing, one end of the carbon rod 103 is fixed to the steel cap 101C' and is in electrical communication with the steel cap 101C', and another end of the carbon rod 103 extends into the housing and, when the housing is filled with the electrolyte 104, is in electrical communication with the electrolyte 104 in the housing.

[0060] As shown in FIGS. 1 and 2 , a cylindrical conductive lining 102 is positioned within the cylindrical section 101A of the housing. Here, the cylindrical conductive lining 102 rests on or adjacent to the inner surface of the cylindrical section 101A of the housing, closely complementing the inner surface of the housing. The conductive lining 102 has six spaced-apart notched slots 102A that extend substantially parallel to one another along the longitudinal axis of the conductive lining 102. During manufacture of the battery of this embodiment, the conductive lining 102 is inserted into the chamber of the housing through the open first end of the cylindrical section 101A before the first end portion of the housing is movably attached to the first end of the cylindrical section 101A of the housing.

[0061] The cylindrical conductive lining 102 is formed by rolling up a zinc sheet having the approximate dimensions of 0.5 mm thick, 45 mm long, and 35.5 mm wide, as shown in FIG. 4 . The cutout slots 102A are approximately 35 mm long and 2 mm wide, respectively. When the zinc sheet is rolled into a cylindrical shape, the diameter of the zinc lining is approximately 11.3 mm. In an alternative embodiment of the present invention, instead of a slot, a cutout or a series of holes may extend along the elongate length of the conductive lining. In this embodiment, the slot is formed as a cutout in the zinc sheet, but it is contemplated that the slot may be integrally formed in the zinc sheet using a molding technique. Alternatively, the overall shape and configuration of the conductive lining, including the slot, cutout, or series of holes, may be formed as a composite of two or more different zinc sheets bonded together using any suitable technique. The novel construction of the plastic housing with conductive lining 102 offers advantages over existing batteries with all-metal housings in terms of reduced manufacturing costs (due to the use of less metal) and reduced overall battery weight, without compromising battery performance.

[0062] A permeable separator sheet 105 is positioned adjacent to the conductive lining within the battery housing. In this case, the conductive lining 102 is positioned between the permeable separator sheet 105 and the inner surface of the housing. The permeable separator sheet 105 is formed by rolling two layers of 0.08 mm kraft paper into a cylindrical form. The permeable separator sheet 105 can be slid into the chamber of the housing during battery manufacture when the first end portion 101B is not yet attached to the first end of the housing. In alternative embodiments, synthetic polymer or natural polymer materials can be used. The portion of the permeable separator sheet 105 positioned adjacent to the second end of the housing is folded to form an envelope containing particles of electrolyte 104. The particles of electrolyte 104 are injected into the battery housing from the first end of the housing through the first end of the cylindrical section 101A of the housing before being sealed by the first end portion 101B.

[0063] The electrolyte 104 includes a metal oxide powder, such as manganese dioxide, iron oxide, or crystalline silver oxide. In this embodiment, the electrolyte includes, by weight of the electrolyte, approximately 3% ammonium chloride particles, 16% zinc chloride particles, 68% manganese dioxide particles, 12.4% acetylene carbon black particles, and 0.6% zinc oxide particles.

[0064] The electrolyte 104 was ball milled using a rotary or planetary ball mill and ceramic balls such as agate (carnelian). During testing, a 500 ml laboratory ball mill was used with ceramic milling balls weighing 110 g and having a diameter of 22.4 mm, or smaller balls weighing 190 g and having a diameter of 10.0 mm. During testing, 150 g of electrolyte was milled in each case. It will be appreciated that the ball milling of the electrolyte 104 can be suitably scaled up to industrial size to accommodate larger-scale production. The electrolyte particles obtained by this ball milling had a diameter in the range of approximately 0.2 mm to 0.8 mm and a density of approximately 1.71 g / cm. 3 ~1.75g / cm 3and a substantially spherical morphology with a water content of approximately 3% or less. Embodiments of the present invention are assembled in a humidity-controlled environment, commonly referred to as a "dry room," to reduce the risk of inadvertent activation of the electrolyte 104 due to moisture.

[0065] Once the particles of electrolyte 104 have been suitably formed according to the process described above, while the first end portion is not yet attached to the cylindrical section 101A, the particles of electrolyte 104 are injected through a funnel into the envelope formed by the permeable separator sheet 105 within the battery housing. In contrast to certain existing equipment and processes that have been used to fill a battery housing by pouring electrolyte powder into the housing, embodiments of the present invention that use the electrolyte particles described herein tend to reduce the incidence of particle clogging in the funnel, reducing delays in the manufacture of such batteries. Furthermore, it has been found that electrolyte particles shaped and sized according to embodiments of the present invention tend to allow water to naturally infiltrate through the electrolyte mass within the housing more easily than other existing water-filled batteries.

[0066] During or after the particles of electrolyte 104 are injected into the envelope of the permeable separator sheet 105, the housing is shaken or vibrated to help settle the particles of electrolyte 104 within the envelope of the permeable separator sheet 105 and maximize the amount of particles of electrolyte 104 stored within the housing. A plunger can be used to help further force the particles of electrolyte 104 into the housing, although this step may not be necessary to deliver a suitable amount of particles of electrolyte 104 into the battery housing. Once the particles of electrolyte 104 are injected into the envelope formed by the permeable separator sheet 105, the carbon rod 103 extending from the cathode terminal 101C' into the housing and into the envelope is surrounded by the particles of electrolyte 104 so as to be in electrical communication with the electrolyte 104.

[0067] Once the required amount of electrolyte is injected into the housing, the permeable separator sheet 105 is folded over the particles of electrolyte 104 at the first end of the housing to substantially enclose the electrolyte powder 104 within the envelope. FIG. 1 shows a tapered coil spring 106 that is then inserted into the housing, with the base 106A of the coil spring 106 resting on the folded portion of the permeable separator sheet 105 enclosing the electrolyte 104, as shown in FIG. 2. The base 106A of the coil spring 106 is wide enough to be in electrical communication with the conductive lining 102 within the cylindrical section 101A of the housing. The tapered end 106B of the coil spring 106 is configured to be in electrical communication with the metallic core 200A of the first end portion 101B when the first end portion 101B is attached to the first end of the housing. Advantageously, the presence of the coil spring 106 not only assists in retaining the folded permeable separator sheet 105 over the electrolyte, but the coil spring 106 is also configured to provide direct electrical communication between the conductive lining 102 and the anode terminal 200A provided by the metallic core 200A located in the first end portion 101B of the housing. This provides a notable improvement over certain other flooded batteries in which a "membrane" or "retaining member" is used to retain the folded permeable separator sheet within the battery, but which does not provide direct electrical communication between a conductive surface within the housing and the battery's anode terminal.

[0068] Once assembled, battery embodiments are kept unused until water ingress into the housing occurs in accordance with the operation of the battery described above. Conveniently, elongated cutout slots 102A in conductive lining 102 allow water delivered into the housing to flow relatively freely and evenly along the length of cylindrical section 101A of the housing, such that the overall contact surface area between the water and electrolyte 104 is improved as the water passes through cutout slots 102A and into contact with electrolyte 104. Permeable separator sheet 105 wicks water from areas along the length of cutout slots 102A in conductive lining 102, allowing it to subsequently contact electrolyte 104 through permeable separator sheet 105. For example, in contrast to certain existing flooded batteries that use corrugated metal sheets within the housing, allowing water to be drawn along the battery housing via the valleys of the corrugations, the use of cutout slots 102A in conductive lining 102 in embodiments of the present invention tends to provide at least equivalent water flow within the housing while at the same time mitigating loss of electrolyte storage capacity within the housing. Additionally, the use of cutout slots 102A in conductive lining 102 (as opposed to the use of corrugations in the conductive sheet of existing batteries) allows for less overall metal usage, which in turn reduces the overall cost per manufactured unit and the overall weight of batteries according to embodiments of the present invention.

[0069] Once the water is in suitable contact with the electrolyte within the housing, the activated electrolyte 104 chemically reacts with the conductive lining 102 through the permeable sheet 105, thereby generating a potential difference between the electrically insulated conductive rods 103 and the conductive lining 102. The permeable separator sheet 105, located between the conductive lining 102 and the conductive rods 103, physically and electrically isolates the conductive lining 102 and the conductive rods 103 from each other, while allowing the free flow of positive ions resulting from the chemical reaction therebetween in a direction from the conductive lining 102 through the permeable separator sheet 105 toward the conductive rods 103, thereby continuing to generate and maintain the potential difference. Thus, electrons can flow from the battery through a load device to power the load device.

[0070] Because battery embodiments of the present invention are kept unused until use, such battery embodiments advantageously enjoy a shelf life that lasts significantly longer than conventional, off-the-shelf types of batteries intended for similar use, which, in contrast, tend to degrade in performance much more quickly during storage due to the activation of the electrolyte powder mixture at the time of manufacture. While the longer shelf life of the present invention embodiments described herein makes them particularly well suited and intended for use in emergency situations, the actual power output capabilities of such battery embodiments may match or exceed the power output expected from certain conventional batteries.

[0071] Advantageously, the structural design and material composition of batteries according to embodiments of the present invention also facilitate the reusability and recyclability of their components. Various components of the battery can be quickly and efficiently detached from one another using automated machinery. The separated components can then be collected, returned to the factory, and reused in the manufacture of new batteries, eliminating the time, cost, and energy required to recycle such components. Further cost savings can be achieved by collecting these reusable components and shipping them in bulk to factories in relatively cost-effective manufacturing jurisdictions.

[0072] Those skilled in the art will appreciate that the invention described herein is capable of variations and modifications other than those specifically described without departing from the scope of the invention. All such variations and modifications that become apparent to those skilled in the art should be considered to be within the spirit and scope of the invention as broadly described above. The invention should be understood to include all such variations and modifications. The invention also includes all of the steps and features referred to or shown herein, individually or collectively, and any and all combinations of any two or more of the steps or features.

[0073] The reference in this specification to any prior art is not, and should not be taken as, an acknowledgment or in any way suggestion that that prior art forms part of the common general knowledge.

Claims

1. A battery, a housing having an interior surface defining a chamber within which an electrolyte is disposed; a conductive surface located within the chamber adjacent the inner surface of the housing, the conductive surface being configured to electrically connect with an anode terminal of the battery; a permeable separator sheet positioned within the housing and configured to electrically insulate the electrolyte from the conductive surface; a conductive rod having a first end configured to electrically connect to a cathode terminal of the battery and a second end configured to electrically connect to the electrolyte; an opening disposed in the housing to allow liquid to enter the chamber and activate the battery by creating a potential difference between the conductive surface and the conductive bar; the conductive surface has a slot extending substantially along a longitudinal axis of the conductive surface and includes a conductive lining positioned adjacent the permeable separator sheet; The slot extends through the conductive lining.

2. the housing comprises a plastic material; The battery of claim 1 .

3. the conductive surface comprises a zinc material; The battery according to claim 1 or 2.

4. the anode terminal is disposed at a first end portion of the housing; the first end portion comprises a combination of plastic and metal materials; The battery according to any one of claims 1 to 3.

5. 5. The battery of claim 4, wherein the plastic material concentrically surrounds a core formed by the metallic material.

6. a spring positioned within the housing and configured to provide an electrical connection between the conductive surface of the housing and the anode terminal; The battery according to any one of claims 1 to 5.

7. The battery of any one of claims 1 to 6, wherein the electrolyte comprises substantially spherical particles having a diameter in the range of 0.2 mm to 0.8 mm.

8. The electrolyte has a density of 1.71 g / cm ３ ~1.75g / cm ３ 8. The battery of claim 7, comprising particles in the range of

9. The particles have a moisture content of 3% or less. The battery according to claim 7 or 8.

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