High Efficiency Nickel-Iron Battery

A method for manufacturing an iron electrode for use in an iron-based rechargeable battery, the method comprising:

• combining carbonyl iron powder with a at least one additive to create an electrode-forming blend;
• coating a metallic mesh with the electrode-forming blend;
• and
• sintering the electrode-forming blend under an oxygen-free atmosphere to form the iron electrode.

A method comprising:

• combining carbonyl iron having an oxide content that is less than about 0.3 weight percent with one or more additives and an optional binder to form an electrode-forming blend, the carbonyl iron having iron particles with an average particle size from about 2 to 5 microns;
• introducing the electrode-forming blend into the mold having a nickel or nickel-coated mesh positioned therein;
• and
• pressing the electrode-forming blend at a temperature 140°-180° C. under a pressure of 50-200 psi to form an iron electrode with the mesh impregnated therein.