Development of a novel composite aluminum anode

This paper presents a novel composite fabrication of aluminum anodes for use in moderate rate Al/Air cells in alkaline media. The polymer composite/particulate aluminum structure allows control of electrolyte contact with the aluminum surfaces during discharge. This ability could lead to improved deliverable energy density and allow the anode discharge characteristics, in some measure, to be tailored to need. A limited first round lab testing of these composite anodes has been carried out. Current capabilities were moderate, ranging up to about 2 mA/cm(2). Observed cell discharge potentials were mostly above I V. Delivered energy densities were generally comparable to those of planer anodes of comparable metal weight and alloy. It is of particular significance, however, that the discharge lifetimes of the composite anodes for certain formulations, on a per grain basis, were considerably longer than those of their planer counterparts. Further formulation optimization and fabrication uniformity should lead to improved energy density and lifetime. (C) 2003 Elsevier B.V. All rights reserved.