Patent ID: 8883346

Claim:
A method of manufacturing a prismatic battery comprising: stacking positive electrode plates, negative electrode plates, and separator layers therebetween, wherein: the positive electrode plates extend beyond a periphery of the electrode stack, and the positive electrode plates are arranged such that the portions of the positive electrode plates that extend beyond the periphery of the electrode stack are aligned with one another, with the positive electrode plates comprising manganese dispersed throughout a compressed metal foam which is compressed between about 42 and 45% of the original thickness; and the negative electrode plates extend beyond a periphery of the electrode stack, and the negative electrode plates are arranged such that the portions of the negative electrode plates that extend beyond the periphery of the electrode stack are aligned with one another, with the negative electrode plates comprising zinc dispersed throughout a compressed metal foam which is compressed between about 42 and 45% of the original thickness; fusing the portions of the positive electrode plates that extend beyond the periphery of the electrode stack to form positive current collectors; and fusing the portions of the negative electrode plates that extend beyond the periphery of the electrode stack to form negative current collectors.