Abstract:
One aspect includes a zinc-air battery that includes a gas-permeable barrier sheet first layer, a cathode collector second layer disposed facing the gas-permeable barrier sheet first layer, a cathode puck third layer disposed facing the cathode collector second layer, a separator fourth layer disposed facing the cathode puck third layer, a zinc fifth layer disposed facing the separator fourth layer, an anode collector sixth layer disposed facing the zinc fifth layer; and a housing surrounding at least the first, second, third, fourth, and fifth layers and comprising a gas-permeable housing first end disposed facing the barrier sheet first layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a non-provisional of and claims the benefit of U.S. Provisional Application No. 62/101,309, filed Jan. 8, 2015, entitled Zinc-Air Battery Systems and Methods. This application is hereby incorporated herein by reference in its entirety and for all purposes. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
       [0002]      FIG. 1 a    is an exemplary perspective drawing illustrating an embodiment of a battery. 
         [0003]      FIG. 1 b    is an exemplary perspective drawing illustrating the battery of  FIG. 1 a    coupled to a smartphone. 
         [0004]      FIG. 2 a    is an exemplary perspective drawing illustrating the battery of  FIGS. 1 a  and 1 b    associated with an adapter. 
         [0005]      FIG. 2 b    is an exemplary perspective drawing illustrating the battery of  FIGS. 1   a,    1   b  and  2   a  coupled with the adapter of  FIG. 2 a    and associated with a power cord. 
         [0006]      FIG. 3 a    illustrates an exploded perspective view of a battery in accordance with another embodiment. 
         [0007]      FIG. 3 b    illustrates a perspective view of the battery of  FIG. 3 a    in an assembled configuration. 
         [0008]      FIG. 4 a    illustrates a perspective view of a frame of the battery of  FIGS. 3 a    and  3   b.    
         [0009]      FIG. 4 b    illustrates a cross-section perspective view of the frame of  FIG. 4   a.    
         [0010]      FIG. 5 a    illustrates a perspective view of a barrier of the battery of  FIGS. 3 a    and  3   b.    
         [0011]      FIG. 5 b    illustrates a cross-section perspective view of the barrier of  FIG. 5   a.    
         [0012]      FIG. 6  illustrates a perspective view of the barrier and frame of  FIGS. 4 a    and  4   b.    
         [0013]      FIG. 7 a    illustrates a perspective view of a cathode of the battery of  FIGS. 3 a    and  3   b.    
         [0014]      FIG. 7 b    illustrates a cross-section perspective view of the cathode of  FIG. 7   a.    
         [0015]      FIG. 8 a    illustrates an exploded perspective view of a zinc layer, anode collector and can of the battery of  FIGS. 3 a    and  3   b.    
         [0016]      FIG. 8 b    illustrates a perspective view of the zinc layer, anode collector and can of  FIG. 8 a    in an assembled configuration. 
         [0017]      FIG. 9  illustrates an exploded perspective view of a battery in accordance with a further embodiment. 
         [0018]      FIG. 10  illustrates a perspective view of the battery of  FIG. 9  in an assembled configuration. 
         [0019]      FIG. 11  illustrates a cross sectional side view of the batteries of  FIGS. 9 and 10 . 
         [0020]      FIG. 12  illustrates a cross sectional perspective view of an anode cap of the battery of  FIGS. 9, 10 and 11 . 
         [0021]      FIG. 13  illustrates an exploded perspective view of a battery in accordance with another embodiment. 
         [0022]      FIG. 14 a    illustrates a perspective view of the battery of  FIG. 13  in an assembled configuration. 
         [0023]      FIG. 14 b    illustrates a cut-away perspective view of the battery of  FIGS. 13 and 14   a.    
         [0024]      FIG. 15  illustrates an exploded perspective view of a battery in accordance yet another embodiment. 
     
    
       [0025]    It should be noted that the figures are not drawn to scale and that elements of similar structures or functions are generally represented by like reference numerals for illustrative purposes throughout the figures. It also should be noted that the figures are only intended to facilitate the description of the preferred embodiments. The figures do not illustrate every aspect of the described embodiments and do not limit the scope of the present disclosure. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0026]    Turning to  FIG. 1   a,  a battery  100  is shown in one example embodiment  100 A as comprising battery body  105  disposed in a cartridge  110 . The battery body  105  is shown having a face  106  comprising a plurality of vents  107 . The battery body  105  is disposed in a tray  111  defined by the cartridge  110 , which further defines a rim  112  that peripherally surrounds the face  106  of the battery body  105  on cartridge top and bottom ends  113 ,  114  and cartridge sides  115 . The cartridge top end  113  comprises an elongated coupling slot  116  defined by the cartridge  110  that extends between the top and bottom face  117 ,  118  of the cartridge  110 . 
         [0027]    In various embodiments, the coupling slot  116  can correspond to a locking post  120  as illustrated in  FIGS. 1   b,    2   a  and  2   b.  Turning to  FIG. 1   b,  the battery  100  can be configured to power various devices including a smartphone  125 , which is shown disposed in a battery case  135 , which can be configured to operably accept the battery  100 A in a case tray  136  defined by the battery case  135 . In other words, the battery  100 A can be configured to snap into the tray  136  and around the locking post  120  to deliver power to the smartphone  125 . 
         [0028]    Accordingly, the example battery case  135  of  FIG. 1   b,  can be operably connected to the smartphone  135  such that when the battery  100 A is coupled with the case  135 , electrical power generated by the battery  100 A can be communicated to the smartphone  125  via the case  135  such that the battery  100 A powers the smartphone in part or in whole. For example, in some embodiments, the smart phone can comprise one or more power source (e.g., a battery) and the battery  100 A can provide additional power to the smart phone  135  and/or completely power the smartphone  135 . 
         [0029]    As discussed in more detail herein, in various embodiments, a power system can comprise a plurality of batteries  100  that are configured to removably couple with various devices (e.g., smartphones) to provide power to such devices. Such a system can be configured to provide power to such devices when one or more device power source is exhausted or depleted. 
         [0030]    For example, when a user is running out of battery power on his smartphone  135 , the user can attach a battery  100 A to the battery case  135  on the smartphone  135  to provide power to the smartphone  135  to extend the operating life of the smartphone  135 . Where a first battery  100 A becomes depleted or exhausted, the user can swap a second battery  100 A in place of the first battery  100 A to further extend the operating life of the smartphone  135 . Accordingly, by swapping out a plurality of batteries  100 A on the case  135 , the operating life of the smartphone  135  can be extended indefinitely, even if a battery of the smartphone  135  is depleted or exhausted. 
         [0031]    Such a power system can be desirable because it can allow a user to continuously power a device without the necessity of charging a primary battery associated with the device. In some examples, a user can carry one or more battery  100  as a backup in case a primary battery associated with a device is depleted or exhausted and/or to replace depleted or exhausted backup batteries  100 . In further examples, batteries  100  can be available at retail locations, from street vendors, via vending machines, via drone, via courier, or the like. In various examples, a user can identify, via an application, people and/or retailers that can provide the user with one or more battery  100 . In some examples, batteries can be delivered to the user&#39;s location and/or the user can travel to a location where batteries are available. 
         [0032]    Although a smartphone  135  is discussed as a device that can be powered by such a power system and/or battery  100 , in further embodiments, any suitable device can be powered by a battery  100 , including a tablet computer, a laptop computer, a smartwatch, a headset computer, a virtual reality system, a gaming device, a vehicle, a drone, an audio player, a body monitor, a work tool, or the like. Accordingly, in various embodiments, batteries  100  can take on various suitable sizes, shapes, and types. Some specific embodiments of batteries  100  having flat prismatic shape are described in the present disclosure, but should not be construed to be limiting on the wide variety of batteries  100  that are within the scope and spirit of the present invention. 
         [0033]    Turning to  FIGS. 2 a    and  2   b,  for example, the battery  100 A of  FIGS. 1 a  and 1 b    can be configured to operably couple with an adapter  200 . The adapter  100  can be configured to directly interface with one or more devices to provide power to the device, or as shown in  FIG. 2   b,  the adapter  200  can be configured to provide power to various devices via a power cord  250  that can couple with the adapter  200 . In further examples, the adapter  200  can be configured to provide power to various devices wirelessly via inductive coupling, or the like. 
         [0034]    In various examples, the adapter  200  can comprise a coupling rim  205  that comprises the locking post  120  disposed on a shelf  206 . The shelf  206  can be perpendicular to a back wall  207 . As illustrated in  FIG. 2   a,  the coupling slot  116  can engage the coupling rim  205  and the top end  113  of the battery  100 A can engage the back wall  207 , with a portion of the rear face  118  of the battery  100 A engaging the shelf  206 . 
         [0035]      FIGS. 1   a,    1   b,    2   a  and  2   b  illustrates an example battery  100 A that is planar and rectangular with rounded corners and having a single elongated coupling slot  116  that extends parallel to the top end of the battery  100 A. However, further embodiments can be of any suitable shape and size. Further embodiments can comprise a plurality of coupling slots  116 , or a coupling slot  116  can be absent. Additionally, various suitable coupling structures can be present on a battery  100  in some embodiments. 
         [0036]    In various embodiments, it can be desirable for devices, adapters and/or batteries of a power system to have complementary coupling structures. For example, in some embodiments, complementary coupling structures can provide for standardized couplings that can be the basis for a proprietary power system. In some embodiments, various complementary couplings can provide for batteries of a certain power profile (e.g. voltage and/or ampere output) to only be coupled with devices and/or adapters that are configured for that battery. In other words, batteries  100  having different power profiles can have different complementary couplings. 
         [0037]    Additionally, in various embodiments, batteries  100  can be of any suitable battery type and may or may not be rechargeable. For example, a battery  100  can comprise a lead acid battery, a lithium ion battery, a nickel metal hydride battery, a zinc-air battery, or the like. The following discussion illustrates some examples of zinc-air batteries in accordance with various embodiments, but such disclosure should not be construed to be limiting on the many types of batteries that are within the scope and spirit of the present invention. 
         [0038]      FIGS. 3 a  and 3 b    illustrate a battery  100  in accordance with one example embodiment  100 B. The battery  100 B is shown comprising a plurality of layered elements including a frame  310 , a barrier  320 , a cathode  330 , a separator  340 , a zinc layer  350 , an anode collector  360 , and a can  370 . 
         [0039]    As illustrated in  FIGS. 3   a,    3   b,    4   a,    4   b  and  6  the frame  310  can comprise a cathode exit  311  defined by an outer wall  405  of the frame  310 . In this example, as shown in the cross sectional view of  FIG. 4   b,  the frame  310  can have an L-shaped cross section defined by an outer wall lip  410  that extends perpendicularly to a flange portion  415  that extends into and defines an orifice  312 . The lip  410  and flange portion  415  can define a notch  420 . The frame can comprise various suitable materials, including plastics such as polypropylene (PP), or the like. The frame  310  can be made in any suitable way, including injection molding, or the like. 
         [0040]    As illustrated in  FIGS. 3   a,    3   b,    5   a,    5   b  and  6 , the barrier  320  can comprise a planar barrier sheet  321  having an adhesive  322  disposed about the edge  510  of a first face  515  of the barrier sheet  321 . The barrier sheet  321  can comprise various suitable materials in various embodiments. In some embodiments, it can be desirable for the barrier sheet to comprise a material that is not liquid transmissive, but is gas transmissive. In other words, in some embodiments, the barrier sheet  321  can allow various gasses to pass through the barrier sheet  321  (e.g., between a first and second face  515 ,  520 ), but prevent liquids such as water from passing through the barrier sheet  321 . As discussed in more detail herein, a gas transmissive barrier sheet  321  can be desirable because it can provide for functioning of the battery  100 B by allowing various gasses to contact internal portions of the battery  100 B to generate an electrical current. In some preferred embodiments, the barrier sheet  321  can comprise polytetrafluoroethylene (PTFE), ePTFE (proprietary polytetrafluoroethylene by W. L. Gore &amp; Associates), and the like. 
         [0041]    The adhesive  322  can comprise any suitable adhesive, including a glue, wax, epoxy, acrylic, silicone, rubber, VHB (3M, Inc.) or the like. For example, in one preferred embodiment, the adhesive  322  can comprise a pressure sensitive adhesive (PSA) or epoxy. As illustrated in  FIG. 6 , the barrier  320  can be configured to reside within the notch  420  defined by the frame  310 . Additionally, the adhesive  322  can be configured to couple with the notch  320  via the lip  410  and/or flange portion  415  that define the notch  320 . In some embodiments, a width of the adhesive  322  can correspond to a width of the flange portion  415 , such that the adhesive does not substantially extend into the orifice  312  defined by the frame  310 . 
         [0042]    Additionally, in various embodiments, a thickness of the adhesive  322  and barrier sheet  321  can correspond to the cathode exit  311  defined by the outer wall  405  of the frame  310 . For example, the thickness of the adhesive  322  and barrier sheet  321  can allow the adhesive  322  and barrier sheet  321  to reside within the notch  320  of the frame  310 , without the adhesive  322  and barrier sheet  321  obstructing the cathode exit  311 . In further embodiments, the barrier sheet  321  can be coupled to the frame  310  via an ultrasonic weld or other suitable coupling method. 
         [0043]    As illustrated in  FIGS. 3   a,    3   b,    7   a  and  7   b  the cathode  330  can comprise a cathode collector plate  331  that includes a cathode terminal  332  and a cathode puck  333 . In various embodiments, the cathode collector plate  331  can comprise any suitable metal or other conductive material. For example, in one preferred embodiment, the cathode collector plate  331  can comprise nickel. The cathode collector plate  331  can be in various suitable configurations and formed in various suitable ways in accordance with various embodiments. For example, in some embodiments, the cathode collector plate  331  can comprise a mesh that is configured to allow gas, fluid or other matter to pass through the collector plate  331  and contact the cathode puck  333 . For example, in various embodiments, having a mesh collector plate  331  can be desirable so that air can reach the cathode puck  333  to facilitate a chemical reaction for generating electrical current. 
         [0044]    The cathode puck  333  can comprise various suitable materials in various embodiments. For example, in one preferred embodiment, the cathode puck  333  can comprise carbon, manganese, and polytetrafluoroethylene (PTFE). In another preferred embodiment, the cathode puck  333  can comprise catalytic carbon manganese dioxide. 
         [0045]    As illustrated in  FIGS. 3   a,    3   b,    8   a  and  8   b  the battery  100 B can comprise a zinc layer  350 , an anode collector  360 , and a can  370 .  FIGS. 3 a  and 8 a    illustrate an exploded view of the zinc layer  350 , anode collector  360 , and can  370  and  FIG. 8 b    illustrates a cross sectional view of the zinc layer  350 , anode collector  360 , and can  370  in an assembled configuration. As shown in  FIG. 8   b,  the anode collector  360  can be disposed within a tray  374  of the can  370  and can engage a base  375  of the can  370 . The anode collector  360  can comprise an anode terminal  361 , which can extend through an anode terminal slot  371  defined by the can  370 . The zinc layer  350  can be disposed within the tray  374  of the can  370  over the anode collector  360 . 
         [0046]    In various examples, the zinc layer  350  can comprise a zinc slurry. For example, in one embodiment, the zinc layer  350  can comprise a semiliquid mixture of zinc particles suspended in potassium hydroxide or other suitable liquid. The anode collector  360  can comprise various suitable materials, including conductive materials such as metals. For example, in one preferred embodiment, the anode collector  360  can comprise brass. 
         [0047]    The separator  340  ( FIG. 3 a   ) can be disposed over the zinc layer  350  in the tray  374  of the can  370 . The separator  340  can comprise various suitable materials. The separator  340  can be rigid or flexible in some embodiments. Additionally, in some embodiments, the separator  340  can be fluid, gas and/or liquid permeable, semi-permeable or non-permeable. In various embodiments, it can be desirable to select a material for the separator  340  that is thin and wets well. In some embodiments, the separator can comprise a fabric, paper, or the like that can comprise non-woven wood pulp and/or synthetic fibers which may or may not be reinforced with a binder. For example, in one preferred embodiment, the separator  340  can comprise a KimWipe Wiper (Kimberly-Clark Professional, Inc.). 
         [0048]    As illustrated in exploded view of  FIG. 3   a,  the cathode  330  can be layered on the separator  340 , with the frame  310  and barrier  320  layered on the cathode  330 . The cathode terminal  332  can extend through the cathode exit  311  defined by an outer wall  405  and a cathode slot defined by the can  370 . In various embodiments, the frame  310  can be configured to engage a shelf  373  defined by can  370  such that a top face of the frame  310  is parallel to a top face of a rim of the can  370 . The frame  310  can be coupled to the can via a weld, adhesive, friction fit, or other suitable coupling method. An example assembled battery  100 B is illustrated in  FIG. 3   b.    
         [0049]      FIGS. 9-12  illustrate a battery  100  in accordance with another embodiment  100 C. As illustrated in  FIG. 9 , the battery  100 C can comprise a cathode can  910  that comprises a tray  911  defined by a rim  912  and a base  913  of the tray  910 . As illustrated in  FIGS. 9 and 13 , in some embodiments, the base  913  of the cathode can  910  can comprise a plurality of ports or holes  914  that extend through the base  913 . 
         [0050]    A barrier sheet  921  can be coupled to the base  913  of the cathode can  910  via an adhesive  922 . In some examples, the adhesive  922  and/or barrier sheet  921  can comprise any of the materials or be configured like the adhesive  322  and barrier sheet  321  discussed above. For example, in one embodiment, the barrier sheet  921  can comprise ePTFE and the adhesive  922  can comprise an epoxy or pressure sensitive adhesive. 
         [0051]    A cathode collector  931  can be positioned over the barrier sheet  921  and a cathode puck  933  can be positioned over the cathode collector. In some embodiments, the cathode collector  931  and/or cathode puck  933  can comprise any of the materials or be configured like the cathode collector  331  and/or cathode puck  333  discussed above. For example, the cathode collector  931  can comprise a nickel mesh and the cathode puck  933  can comprise carbon, manganese, and/or polytetrafluoroethylene (PTFE). In another example, the cathode puck  933  can comprise catalytic carbon manganese dioxide. 
         [0052]    A separator  940  can be positioned over the cathode puck  933  and a zinc layer  950  can be positioned over the separator  940 . In some embodiments, the separator  940  and/or a zinc layer  950  can comprise any of the materials or be configured like the separator  340  or zinc layer  350  discussed above. For example, the separator  940  can comprise a KimWipe material and the zinc layer  940  can comprise a zinc slurry having zinc particles suspended in a liquid such as potassium hydroxide, or the like. 
         [0053]    An anode cap  970  can be positioned over the zinc layer  950  and engage a portion of the rim  912  of the can  910  within the tray  911 . For example, the anode cap  970  can comprise a gasket  980  that surrounds an edge of an anode body  985  of the anode cap  970 , and the gasket can engage a portion of the rim  912  of the can  910  within the tray  911  via friction fit, or the like. In various embodiments, the anode body  985  can comprise any suitable material including a metal. For example, the anode body  985  can comprise nickel, stainless steel plated with nickel and the like. The gasket  980  can comprise any suitable material including rubber, silicone, a plastic, or the like.  FIG. 10  illustrates an example perspective view of an assembled battery  100 B, including the anode cap  970  engaging the rim  912  can  910  via the gasket  980 . 
         [0054]      FIG. 11  illustrates an example cross section of the battery  100 C, which shows a top outer layer defined by the anode body  985  of the anode cap  970 . The anode body  985  is shown in  FIGS. 11 and 12  comprising a planar cap top  1186  with rim  1187  extending away from and perpendicular to the cap top  1186 , the rim  1187  is shown over-molded with the gasket  980  and comprising a terminal curl  1188  that can serve to fix the gasket  980  in place over the rim  1188 . 
         [0055]    The cathode can  910  engage the gasket  980  via a lip  1115  defined by the rim  912  of the cathode can  910 . The gasket  980  further extends downward and engages the cathode collector  931  along a portion of a cathode collector base  1132  and a cathode collector rim  1133  that extends upward and perpendicularly away from the cathode collector base  1132 . The planar cap top  1186 , the gasket  980  and the cathode collector  931  define a cavity  1101 , wherein the zinc layer  950 , the separator  940 , and cathode puck  933  are disposed. More specifically, the zinc layer  950  is disposed on the separator  940 , and the separator is disposed on the cathode puck  933 , which is disposed on the collector base  1132  of the cathode collector  931 . 
         [0056]    The cathode collector  931  engages the rim  912  of the cathode can  910  to collectively form an anode  1102 . An anode cavity  1103  is defined between the cathode collector base  1132  and the cathode can base  913 . The barrier  921  and adhesive  922  are disposed within the anode cavity  1103  with the adhesive  922  coupling an edge of the barrier  921 . In various embodiments, the cathode collector  931  can apply pressure to the barrier  921  and adhesive  922 , which can be desirable for generating a better seal between the barrier  921 , adhesive  922 , and cathode can  910 . 
         [0057]    As illustrated in  FIG. 11 , in various embodiments, gas can penetrate the battery  100 C via the one or more ports  914  defined by the can base  913  and reach the cathode puck  933 . Allowing gas, such as air or the like, to reach the cathode puck  933  can be desirable because it can provide for a chemical reaction between the gas and the cathode puck  933 , which can facilitate generation of an electrical current. 
         [0058]    As discussed herein and as illustrated in  FIG. 9  the adhesive  922  can be disposed on an outer edge of the barrier  921 , which exposes a portion of the barrier  921  to gas entering the ports  914 . The barrier  921  can be configured to be gas permeable, which can allow the gas to pass through the barrier  921 . In some embodiments, the barrier can be configured to be non-transmissive for liquids, solids and the like. Additionally, the cathode collector  931  can comprise a mesh configuration, or the like, which can provide a plurality of passages through the cathode collector  931 . Accordingly, gas can pass through the cathode collector  931  and contact the cathode puck  933  to facilitate a chemical reaction to generate electrical current. 
         [0059]      FIGS. 13, 14   a  and  14   b  illustrate another embodiment of a battery  100  in accordance with another embodiment  100 D. The battery  100 D comprises a chassis  1370 , that comprises a tray  1371  defined by a rim  1372  and a base  1373  of the tray  1371 . The chassis  1370  can also comprise one or more fill port  1374 , in which a respective plug  1375  can reside. The chassis  1370  can also comprise respective cathode an anode terminal ports  1376 ,  1377  and a coupling slot. 
         [0060]    The battery  100 D can also comprise an anode collector  1360  that includes an anode terminal  1360 . The anode collector  1360  can reside at the base  1373  of the chassis  1370  within the tray  1371 , with the anode terminal  1360  extending into and/or through the anode terminal port  1377 . In some embodiments, the anode collector  1360  can comprise any of the materials or be configured like the anode collector  360  discussed above and illustrated in  FIG. 3 . For example, in one preferred embodiment, the anode collector  1360  can comprise brass. 
         [0061]    A zinc layer  950  can be positioned over the anode collector  1360 . In some embodiments, zinc layer  950  can comprise any of the materials or be configured like zinc layers  350 ,  950  discussed above. For example, the zinc layer can comprise a zinc slurry having zinc particles suspended in a liquid such as potassium hydroxide, or the like. 
         [0062]    A cathode  1330  can be positioned over the zinc layer  950  and can comprise a cathode collector plate  1331  that includes a cathode terminal  1332  and a cathode puck  1333 . The cathode  1330  can reside within the tray  1373  of the chassis  1370  with the cathode terminal  1332  extending through the cathode terminal port  1376 . 
         [0063]    In various embodiments, the cathode collector plate  1331  can comprise any suitable metal or other conductive material. For example, in one preferred embodiment, the cathode collector plate  1331  can comprise nickel. The cathode collector plate  1331  can be in various suitable configurations and formed in various suitable ways in accordance with various embodiments. For example, in some embodiments, the cathode collector plate  1331  can comprise a mesh that is configured to allow gas, fluid or other matter to pass through the collector plate  1331  and contact the cathode puck  1333 . For example, in various embodiments, having a mesh collector plate  1331  can be desirable so that air can reach the cathode puck  1333  to facilitate a chemical reaction for generating electrical current. 
         [0064]    The cathode puck  1333  can comprise various suitable materials including carbon, manganese, and/or polytetrafluoroethylene (PTFE). For example, in one embodiment the cathode puck  1333  can comprise catalytic carbon manganese dioxide. In some embodiments the cathode puck  1333  can comprise a wetting or separator layer, which can comprise a fabric, paper, or the like. For example, in some embodiments, the cathode puck  1333  can comprise a separator  340 ,  940  as discussed above, and such a separator can be disposed between the cathode puck  1333  and the zinc layer  1350 . 
         [0065]    A barrier sheet  921  can be positioned over the cathode puck  1333 . In some examples, the barrier sheet  921  can comprise any of the materials or be configured like the barrier sheet  321 ,  921  discussed above. For example, in one embodiment, the barrier sheet  1321  can comprise ePTFE or PTFE. 
         [0066]    A cover  1310  can be positioned over the barrier sheet  1321  and include a top  1311  that defines a plurality of holes or ports  1312  that extend through the top  1311 . The cover  1310  can further comprise a pair of arms  1313  that are configured to couple with respective coupling slots  1387  defined by the rim  1372  of the chassis  1370 . The cover  1310  can be configured to seal the elements between the chassis base  1373  and cover  1310  within the tray  1371  of the chassis  1370 . The cover  1310  and/or chassis  1370  can comprise any suitable materials including a plastic, metal, or the like. 
         [0067]    In some embodiments, a battery  100  can comprise a plurality of battery cells in contrast to a single battery cell as described in embodiments  100 B-D. For example,  FIG. 15  illustrates another embodiment  100 E of a battery  100  that comprises a plurality of battery cells  1501  that comprise a plurality of battery layers  1502 . The cells  1501  can comprise a configuration like any of the batteries described above in embodiments  100 B-D. 
         [0068]    For example, the plurality of layers  1502  of the cells  1501  can include a cathode collector  1531 , a cathode puck  1533 , one or more separator  1540 , a zinc layer  1550 , and an anode collector  1560 . In the example of  FIG. 15 , the battery  100 E includes four cells  1501 ; however, in further embodiments, and suitable plurality of cells or a single cell can be implemented. For example, some embodiments can have one, two, three, five, six, seven, eight, nine or ten cells. 
         [0069]    The cells  1501  can be configured to reside within slots  1504 ,  1506  defined by a respective reinforcing frame  1503  and cell walls  1505 . The cells  1501 , frame  1503  and cell walls  1505  can be surrounded by a barrier sheet  1521 , a cell backing  1507 , a chassis  1570 , one or more cap  1508 , and a cover  1510 . The cover  1510  can be positioned over the barrier sheet  1521  and include a top  1511  that defines a plurality of holes or ports  1512  that extend through the top  1511 . The cover  1510  can further comprise a pair of arms  1513  that are configured to couple with a rim  1572  of the chassis  1570 . The cover  1510  can be configured to seal the cells  1501  between the chassis  1570  and cover  1310 . 
         [0070]    The chemical and hardware elements of batteries  100  can comprise any suitable configuration that provides for generation of an electrical current. Additionally, while the example, of a zinc-air battery is used herein, it should be clear that alternative battery types, chemistries, and battery configurations are also within the scope and spirit of the present disclosure. 
         [0071]    In various embodiments, a zinc layer  350 ,  950 ,  1350 ,  1550  can include various suitable compositions. For example, a zinc layer  350 ,  950 ,  1350 ,  1550  can comprise a slurry or gel that includes of a blend of amalgamated zinc grains and potassium hydroxide. In one example, a potassium hydroxide electrolyte gel can include 18 M-Ohm deionized water; zinc grains doped with indium and/or bismuth (e.g., Grillo Werk Aktiengesellschaft, #000010-600376); carboxymethylcellulose and sodium salt (e.g., High Viscosity, Sigma CAS #9004-32-4); and potassium hydroxide 90%. 
         [0072]    In one example, a zinc slurry or gel can be made by preparing a solution of 11 M potassium hydroxide and 1.6% wt carboxymethylcellulose and mixing 0.69% wt powdered zinc with 0.31% wt of the prepared solution. Further embodiments can employ suitable compositions, system and methods from U.S. Patent Publication US 2011/0123902 of U.S. application Ser. No. 12/919,214 filed May 26, 2011, which is hereby incorporated by reference in its entirety and for all purposes. 
         [0073]    The described embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the described embodiments are not to be limited to the particular forms or methods disclosed, but to the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives.