A solid porous zinc electrode for use in alkaline-zinc batteries, zinc-air
batteries and fuel cells is provided which comprises specific zinc
filaments, fibers, threads or strands compressed into a physically-stable
wooly mass to form the electrode with a controlled geometrical shape and
porosity distribution. Differential densification incorporates ribs,
borders, grids or tabs for good structural integrity, mechanical
strength, electrochemical behavior, and electrical conductivity. Pressing
in a mold or rolling of a compressed sheet can also provide an anode with
a large anode/cathode interface area and a complex geometry. The
filaments of controlled dimension and composition are preferably made by
spin forming from molten zinc alloys. Such anodes are not susceptible to
breakage, have a long storage life and can be used in high rate discharge
applications.