Dual air elecrtrode cell

A leak resistant dual air electrode metal-air cell, comprising:

• a cell casing with an upper and a lower side;
• an upper cathode positioned adjacent to said upper side of said casing;
• a lower cathode positioned adjacent to said lower side of said casing;
• said upper and lower cathodes each having a cathode tab extending out of said casing;
• an upper cathode support member extending parallel to said upper cathode and extending downward along and beyond said casing so as to sandwich said upper cathode tab between said upper side of said casing and said upper cathode support member;
• and
• a lower cathode support member extending parallel to said lower cathode and extending upward along and beyond said casing so as to sandwich said lower cathode tab between said lower side of said casing and said lower cathode support member;
• said cathode tabs being sealed between said upper and lower sides of said cell casing with material of at least one of said upper and lower cathode support members isolating said tabs from one another as said tabs pass through said casing.

A dual air electrode zinc-air cell, comprising:

• a casing including an upper cathode mask wall, a lower cathode mask wall, and a plurality of side walls;
• a zinc anode positioned within said casing;
• said zinc anode enclosed within an anode bag including an upper side and a lower side;
• said anode bag comprising a layer of an absorbent fibrous web surrounding said zinc anode and a layer of a microporous membrane that, when wet, is gas-impermeable and liquid-permeable, surrounding said absorbent fibrous web and said zinc anode;
• an upper air cathode positioned adjacent to said upper cathode mask wall;
• an upper separator layer comprising a layer of an absorbent fibrous web and a layer of a microporous membrane that, when wet, is gas-impermeable and liquid-permeable, positioned between said upper cathode and said upper side of said anode bag;
• a lower air cathode positioned adjacent to said lower cathode wall;
• a lower separator layer comprising a layer of an absorbent fibrous web and a layer of a microporous membrane that, when wet, is gas-impermeable and liquid-permeable, positioned between said lower air cathode and said lower side of said anode bag;
• a gas vent positioned on one or more of said plurality of said side walls of said casing;
• and
• a liquid electrolyte substantially trapped by said absorbent fibrous webs and said microporous membranes.

A trapped electrolyte metal-air cell, comprising:

• a metal anode and one or more air cathodes disposed within a cell casing;
• said metal anode and said one or more air cathodes separated by a predetermined distance;
• said metal anode and said one or more cathodes each being covered on one or more sides with one or more separator layers including an absorbent material;
• said separator layers filling substantially all of the space in said predetermined distance;
• and
• an aqueous electrolyte substantially held adjacent to said anode and said one or more cathodes by said separator layers including said absorbent material.

A case for a metal-air cell with one or more air cathodes with cathode tabs extending therefrom, comprising:

• an upper case member defining a cavity therein;
• a lower case member defining a cavity therein;
• said cavities defining one or more extension adapted to be sealed between said upper and lower case members;
• an upper cathode support member nested in said upper case member cavity and a lower cathode support member nested in said lower case member cavity, such that a pair of said cathode terminal tabs extending out of said case at the same location will be isolated from one another by said one or more extensions.

A dual air electrode metal-air cell, comprising:

• a casing including an upper cathode mask wall, a lower cathode mask wall, and a plurality of side walls;
• said mask walls define a plurality of conically shaped openings;
• an metal anode including an upper side and a lower side positioned within said casing;
• said metal anode covered on at least said upper and lower sides with separator materials;
• an upper air cathode positioned between said upper cathode mask wall and said separator materials on said upper side of said anode;
• a lower air cathode positioned between said lower cathode mask wall and said separator materials on said lower side of said anode;
• a gas vent positioned on one or more of said plurality of said side walls of said casing;
• and
• a liquid electrolyte substantially trapped by said separator materials.