A method of forming an anode comprising zinc for an alkaline cell. The
method involves mixing zinc particles with binders including preferably
polyvinylalcohol, surfactant and water to form a wet paste. The wet paste
is molded into the near shape of the cell's anode cavity and then heated
to evaporate water. A solid porous zinc mass is formed having microscopic
void spaces between the zinc particles. The solid mass can be inserted
into the cell's anode cavity and aqueous alkaline electrolyte, preferably
comprising potassium hydroxide, then added. The solid mass absorbs the
aqueous electrolyte and expands to fill the anode cavity to form the
final fresh anode. Zinc fibers may be added to increase the structural
integrity of the solid mass.