Multifunctional battery and method of making the same

• US 20030049537A1
• Filed: 07/22/2002
• Published: 03/13/2003
• Est. Priority Date: 08/10/2000
• Status: Active Grant

• Current Assignee: University of Virginia Patent Foundation (University of Virginia)
• Original Assignee: University of Virginia Patent Foundation (University of Virginia)
• Inventors: Evans, Anthony G, Queheillalt, Douglas T, Sastry, Ann Marie, Wadley, Haydn N G
• Granted Patent: US 7,211,348 B2
• Time in Patent Office: Days
• US Class Current: 429/238
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/0445 Multimode batteries, e.g. containing auxiliary cells or electrodes switchable in parallel or series connections
• CPC Class Codes: H01M 10/345 Gastight metal hydride accumulators
• CPC Class Codes: H01M 4/02 Electrodes composed of, or comprising, active material
• CPC Class Codes: H01M 4/24 Electrodes for alkaline accumulators
• CPC Class Codes: H01M 4/242 Hydrogen storage electrodes
• CPC Class Codes: H01M 4/32 Nickel oxide or hydroxide electrodes
• CPC Class Codes: H01M 4/385 of the type LaNi5
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/70 characterised by shape or form
• CPC Class Codes: H01M 4/762 Porous or perforated metallic containers
• CPC Class Codes: H01M 50/44 Fibrous material
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

Disclosed herein is a multifunctional battery for supplying power to an electrical circuit, and the related method of making the same. Use of the multifunctional battery permits structural integrity and versatility, while maximizing power output of the cells and minimizing the overall weight of the structure. The multifunctional battery includes an open cell interconnected structure comprised of a plurality of open cells so as to provide a structural electrode. The structural electrode is configured to be a load bearing member. The battery also includes interstitial electrodes that are counter electrodes to the structural electrode. The interstitial electrodes are at least partially received within a predetermined number of the cells of the interconnected structure. Additionally, a separator portion is disposed between the structural electrode and interstitial electrodes to serve as an electrical insulator.

Claims

1. A multifunctional battery for supplying power to an electrical circuit having a first terminal and a second terminal, said battery comprising:

an open cell interconnected structure comprised of a plurality of open cells, wherein said structure comprises a structural electrode, said multifunctional structure being configured to be a load bearing member and being connectable to the first terminal;

at least one or a plurality of interstitial electrodes, said one or plurality of interstitial electrodes being a counter electrode to said structural electrode, said one or plurality of interstitial electrodes being at least partially received within a predetermined number of cells of said structure and being connectable to the second terminal; and

a separator portion disposed between said structural electrode and said interstitial electrodes to serve as an electrical insulator between said structural electrode and interstitial electrodes.

2. The battery of claim 1, wherein said structural electrode and said interstitial electrodes are counter electrodes with respect to one another, wherein:

if said structural electrode is a cathode then said interstitial electrodes are an anode;

or

alternatively, if said structural electrode is an anode then said interstitial electrodes are a cathode.

3. The battery of claim 2, wherein:

said cathode comprises;

a cathode nickel layer, and

a cathode active metal disposed on said cathode nickel layer;

said anode comprises;

a anode nickel layer, and

an anode active metal disposed on said anode nickel layer.

4. The battery of claim 3, wherein:

said cathode active metal comprises nickel-hydroxide; and

said anode active metal comprises metal-hydride.

5. The battery of claim 4, wherein the metal-hydride further comprises an AB₂ or AB₅ alloy.

6. The battery of claim 5, wherein said AB₂ alloy is selected from the group consisting of Ni, Cr, Mn, V, Ti, Zr, Co, and Fe.

7. The battery of claim 5, wherein said AB₅ alloy is selected from the group consisting of Al, Sn, Mn, Co, Cu, Si, Cr, Ce, Nd, Ti, La, and Ni.

8. The battery of claim 1, wherein said separator comprises an electrolyte material.

9. The battery of claim 1, wherein said open cell interconnected network comprises a truss structure.

10. The battery of claim 1, wherein said open cell interconnected network comprise a plurality of truss structures stacked upon one another.

11. The battery of claim 1, wherein said open cell interconnected network comprises a cellular structure.

12. The battery of claim 1, wherein said open cell interconnected network comprise a plurality of cellular structures stacked upon one another.

13. The battery of claim 11, wherein said cellular structure being comprised of woven material.

14. The battery of claim 11, wherein said cellular structure being comprised of textile layers.

15. The battery of claim 14, wherein at least some of said textile layers are a structure selected from the group consisting of woven mesh, square woven mesh, braid mesh, triaxial mesh, and quasi-triaxial mesh.

16. The method of claim 14, wherein said textile layers are three-dimensional elements.

17. The battery of claim 16, wherein at least some of said three dimensional textile layers are a structure selected from the group consisting of braided, multi-ply, triaxial, multi axial, H-beam, I-beam, and honeycomb.

18. A multifunctional battery for supplying power to an electrical circuit having a first terminal and a second terminal, said battery comprising:

a corrugated structure comprised of at least one alternating ridge and groove or a plurality of alternating ridges and grooves, wherein said structure comprises a structural electrode, said multifunctional structure being configured to be a load bearing member and being connectable to the first terminal;

at least one or a plurality of interstitial electrodes, said one or plurality of interstitial electrodes being a counter electrode to said structural electrode, said interstitial electrodes being at least partially received within a predetermined number of grooves of said structure and being connectable to the second terminal; and

a separator portion disposed between said structural electrode and said interstitial electrodes to serve as an electrical insulator between said structural electrode and interstitial electrodes.

19. The battery of claim 18, wherein said structural electrode and said interstitial electrodes are counter electrodes with respect to one another, wherein:

if said structural electrode is a cathode then said interstitial electrodes are an anode;

or

alternatively, if said structural electrode is an anode then said interstitial electrodes are a cathode.

20. The battery of claim 19, wherein:

said cathode comprises;

a cathode nickel layer, and

a cathode active metal disposed on said cathode nickel layer;

said anode comprises;

a anode nickel layer, and

an anode active metal disposed on said anode nickel layer.

21. A method of producing a multifunctional battery for supplying power to an electrical circuit having a first terminal and a second terminal, said battery comprising:

providing an open cell interconnected structure comprised of a plurality of open cells, wherein said structure comprises a structural electrode, said multifunctional structure being configured to be a load bearing member and being connectable to the first terminal;

receiving at least one or a plurality of interstitial electrodes within a number of cells of said structure, said interstitial electrodes being a counter electrode to said structural electrode layer and being connectable to the second terminal;

providing a separator disposed between said structural electrode and said interstitial electrodes to serve as an insulator between said structural electrode layer and said interstitial electrodes.

22. The method of claim 21, wherein said structural electrode and said interstitial electrodes are counter electrodes with respect to one another, wherein:

if said structural electrode is a cathode then said interstitial electrodes are an anode;

or

alternatively, if said structural electrode is an anode then said interstitial electrodes are a cathode.

23. The method of claim 22, wherein:

if said structural electrode is a cathode and said interstitial electrodes are an anode;

then;

said cathode is produced by a method comprising;

depositing a cathode nickel layer on said structure;

providing a cathode active metal on said cathode nickel layer;

said anode is produced by a method comprising;

providing a member configured for said interstitial electrode having an anode nickel layer disposed thereon, and

depositing an anode active metal on said anode nickel layer, and

alternatively, if said structural electrode is an anode and said interstitial electrodes are cathodes;

then

said cathode is produced by a method comprising;

depositing a cathode nickel layer on a member configured for said interstitial electrode;

providing a cathode active metal on said cathode nickel layer;

said anode is produced by a method comprising;

providing said structure having an anode nickel layer disposed thereon, and

depositing an anode active metal on said anode nickel layer.

24. The method of claim 23, wherein said deposition of said cathode nickel layer is applied to said structure or said member by means of a vapor deposition process.

25. The method of claim 24, wherein said deposition process utilizes a carrier gas stream to direct the material vapor.

26. The method of claim 24, wherein said deposition process is directed vapor deposition.

27. The method of claim 23, wherein said deposition of said cathode nickel layer is applied to said structure or said member by a process selected from the group consisting of PVD, CVD, high pressure thermal evaporation, dipping, and high pressure sputtering.

28. The method of claim 23, wherein said deposition of said anode active metal is applied to said anode nickel layer by means of a vapor deposition process.

29. The method of claim 28, wherein said deposition process utilizes a carrier gas stream to direct the material vapor.

30. The method of claim 28, wherein said deposition process is directed vapor deposition.

31. The method of claim 23, wherein said deposition of said anode active metal is applied to said anode nickel layer by a process selected from the group consisting of PVD, CVD, high pressure thermal evaporation, dipping, and high pressure sputtering.

32. The method of claim 23, wherein:

said cathode active metal comprises nickel-hydroxide; and

said anode active metal comprises metal-hydride.

33. The method of claim 32, wherein the metal-hydride further comprises an AB₂ or AB₅ alloy.

34. The method of claim 33, wherein said AB₂ alloy is selected from the group consisting of Ni, Cr, Mn, V, Ti, Zr, Co, and Fe.

35. The method of claim 33, wherein said AB₅ alloy is selected from the group consisting of Al, Sn, M, Co, Cu, Si, Cr, Ce, Nd, Ti, La, and Ni.

36. The method of claim 21, wherein said separator comprises an electrolyte material.

37. The method of claim 21, wherein said open cell interconnected network comprises a truss structure.

38. The method of claim 31, wherein said open cell interconnected network comprise a plurality of truss structures stacked upon one another.

39. The method of claim 21, wherein said open cell interconnected network comprises a cellular structure.

40. The method of claim 39, wherein said open cell interconnected network comprise a plurality of cellular structures stacked upon one another.

41. The method of claim 39, wherein said cellular structure being comprised of woven material.

42. The method of claim 39, wherein said cellular structure being comprised of textile layers.

43. The method of claim 42, wherein at least some of said textile layers are a structure selected from the group consisting of woven mesh, square woven mesh, braid mesh, triaxial mesh, and qrasi-triaxial mesh.

44. The method of claim 42, wherein said textile layers are three-dimensional elements.

45. The method of claim 44, wherein at least some of said three dimensional textile layers are a structure selected from the group consisting of braided, multi-ply, triaxial, multi axial, H-beam, I-beam, and honeycomb.

46. A method of producing a multifunctional battery for supplying power to an electrical circuit having a first terminal and a second terminal, said battery comprising a:

providing a corrugated structure comprised of at least one alternating ridge and groove or a plurality of alternating ridges and grooves, wherein said structure comprises a structural electrode, said multifunctional structure being configured to be a load bearing member and being connectable to the first terminal;

receiving at least one or a plurality of interstitial electrodes, said one or plurality of interstitial electrodes being a counter electrode to said structural electrode, said interstitial electrodes being at least partially received within a predetermined number of grooves of said structure and being connectable to the second terminal; and

providing a separator portion disposed between said structural electrode and said interstitial electrodes to serve as an electrical insulator between said structural electrode and interstitial electrodes.

47. The method of claim 46, wherein said structural electrode and said interstitial electrodes are counter electrodes with respect to one another, wherein:

if said structural electrode is a cathode then said interstitial electrodes are an anode;

or

alternatively, if said structural electrode is an anode then said interstitial electrodes are a cathode.

48. The method of claim 47, wherein:

said cathode comprises;

a cathode nickel layer, and

a cathode active metal disposed on said cathode nickel layer;

said anode comprises;

a anode nickel layer, and

an anode active metal disposed on said anode nickel layer.