Abstract:
A rechargeable metal-air battery having a housing, an air flow path, and at least one metal-air cell positioned within the housing. An air movement device communicated with the housing. The metal-air cell generates oxygen and hydrogen during cell charging. The air movement device creates a pulsating air flow within the air flow path for directing a flow of the generated gases.
Abstract:
A ventilation system for a metal-air battery having a housing for enclosing at least one metal-air cell (10). The housing (20) has at least one air inlet opening (30) and at least one air outlet opening (35). A fan (40) is positioned to force air into the air inlet opening and out of the air outlet opening when the fan is turned on. The openings are sized with a length in the direction through the thickness of the housing being greater than a width in the direction perpendicular to the thickness of the housing. The openings are unobstructed and are sized to eliminate substantially the air flow into the air inlet opening and out of the air outlet opening when the fan is turned off. According to another aspect of the invention, a fan (80) within the battery housing (72) is positioned to distribute air to two separate sets (76-79) of metal-air cells at the same time. In this configuration, all cells of both sets of cells receive air quickly, and the air received is richer in oxygen because the air paths are shorter than in previous configurations utilizing the same number of cells.
Abstract:
A metal-air power supply which provides improved control over air flow is provided. The reactant air and cooling air inlets are separate from one another and isolated from the exhausted reactant and cooling portions of the air flow, the reactant air flow is limited to a volumetric flow rate sufficient to provide from about 3 to about 10 times the stoichiometric amount of oxygen necessary to produce a predetermined level of current from the cell, and a total volumetric flow rate of air sufficient so that the cooling portion of the air flow has a volumetric flow rate from about 10 to about 1000 times the volumetric flow rate of the reactant portion of the air flow is provided. This limits the flow rate of the reactant air over the cathode, isolates the cooling air flow from the reactant air flow, and maintains the temperature of the metal-air cell at a low level without exposing the air cathode to an excessive air flow rate to reduce the likelihood of drying out the metal-air cells, reduce the exposure of the battery cell to contaminants, and minimize the effects of temperature on the vaporization of water within the cell. In a preferred embodiment, the power supply housing and the metal-air cell case form part of the air plenums. A substantially leak-proof metal-air cell is also disclosed.
Abstract:
A dual air electrode metal-air cell having a casing including an upper cathode mask wall, a lower cathode mask wall, and a plurality of side walls; a metal anode with at least upper and lower sides covered with separator materials; an upper air cathode positioned between the upper cathode mask wall and the separator materials on the upper side of the anode; a lower air cathode positioned between the lower cathode mask wall and the separator materials on the lower side of the anode; a gas vent positioned on one or more of the side walls of the casing; and a liquid electrolyte substantially trapped by the separator materials. The separator materials comprise one or more layers of an absorbent fibrous web and one or more layers of a microporous membrane that, when wet, is gas-impermeable and liquid-permeable.
Abstract:
A cathode cover for a metal-air cell of the type having an air cathode positioned along an external surface of a cell case provides for improved control over exposure of the air cathode to air. The cathode cover allows a sufficient amount of air to the air cathode for an adequate production of power from the cell but limits the amount of air to which the air cathode is exposed so as to prevent premature failure of the cell from flooding, drying out, or contamination. In addition, the cathode cover avoids the problems of point diffusion of oxygen through the air cathode and localized electrolytic reactions. The cathode cover includes a mask member defining a plurality of openings therethrough and forming at least one substantially unobstructed air chamber between the mask member and the air cathode. The mask member includes at least about three of the openings per square inch of the air cathode and the openings provide between about 0.001 and about 0.01 square inches of total open area per square inch of air cathode. In addition, the air chamber has at least about 0.033 cubic inches of unobstructed volume per square inch of the air cahtode.
Abstract:
An air manager system is disclosed which maintains a more stable water vapor and carbon dioxide equilibrium across the air cathode of a metal-air cell while still providing new oxygen needed for operation of the cell at desired power levels. Oxygen is preferentially drawn in through one or more ventilation openings (17) in a housing (15), so that the concentrations of water vapor and carbon dioxyde in the battery housing remain more stable, resulting in less transfer across the cathode (30). A fan (20) circulates the gases within the battery housing, keeping the oxygen needed for operation of the cell in contact with the air cathode even though the oxygen concentration within the housing is reduced compared to the ambient air outside the housing. Therefore, the cell is less susceptible to drying out or flooding, and less carbon dioxyde intrudes into the cell.
Abstract:
A vent system for exhausting gas generated within a battery case is provided. The vent system exhausts gas from the battery case (12) while maintaining the hermetic seal of the case. The vent system provides a small gas exit hole (16) that is sufficiently small to prevent electrolyte leakage and also intake of excess carbon dioxide or excess water vapor from the atmosphere. Also, various combinations of gas-permeable, hydrophobic membranes (40, 44) and diffuser material (42) may cover the gas exit hole to provide humidity control for the battery while exhausting gases from the battery. A recess (36) may be provided within the case such that the gas exit hole communicates between the atmosphere and the recess. Also, various combinations of gas-permeable, hydrophobic membranes (40, 44) and diffuser (42) material may cover the recess and gas exit hole to provide humidity control for the battery while exhausting gases from the battery case. The present invention also provides a vent system in which gas-permeable, hydrophobic membranes and diffuser material may fill an opening so as to exhaust gas from the case. The present invention also provides an electrode lead (39) which extends along the battery case and through the seam (34) of the battery case in a manner in which a hermetic seal is provided around the lead. The manufacturing process for the seal around the lead is relatively simple.