Positive Electrode Fabrication for Bi-polar Ni-h2 Cells

Bi-Polar nickel hydrogen design studies indicated a potential improvement in energy density and specific energy if positive electrodes could be manufactured in configurations of twice or more of the present normal thickness. Such electrodes would have to achieve similar active material loading, utilization, and cycle life to conventional 0.8mm I.P.U. nickel hydrogen electrodes. A capability for producing 1.0mm dry sinter and 1.5mm slurry sinter structures on production processes and equipment was demonstrated. The EPI/USAF electrochemical impregnation process proved capable of loading thick electrodes to 1.60 g/cubic centimeters void or higher. Sample electrodes incurred 2000 high rate stress cycles without significant structural or performance degradation. Formation regimes developed for thin plaque are not optimal for thick plaque and further investigation into electrode capacity build-up would seem warranted. Thick electrode technology development is continuing under other programs and shows promise of fulfilling the projected energy density and specific energy improvements.