Zinc-based electrode for alkaline electrochemical cell

An alkaline electrochemical cell comprising:

• a first electrode;
• an alkaline electrolyte;
• and
• a second electrode containing zinc powder having an average particle size substantially greater than 25 micrometers, wherein said zinc powder contains less than 1 weight percent zinc dust of a particle size less than 25 micrometers.

A method of forming a negative electrode for an alkaline electrochemical cell, said method comprising the steps of:

• providing zinc powder;
• substantially removing zinc dust from said zinc powder so that the zinc powder contains less than 1 weight percent zinc dust of a particle size less than 25 micrometers;
• and
• forming a negative electrode with the zinc powder.

A method of manufacturing an electrochemical cell, said method comprising the steps of:

• providing a container with an open end;
• disposing a first electrode within said container;
• inserting a separator within said container and in contact with said first electrode;
• forming a second electrode with a zinc powder containing less than 1 weight percent zinc dust, based on the total weight of zinc, said dust having a particle size less than 25 micrometers;
• disposing said second electrode within said container and physically isolated from said first electrode by said separator;
• disposing an electrolyte within said container and in contact with said first and second electrodes;
• and
• sealing the open end of said container.