MULTI-MODE CHARGING OF HIERARCHICAL ANODE

• US 20120139496A1
• Filed: 11/17/2011
• Published: 06/07/2012
• Est. Priority Date: 11/17/2010
• Status: Active Grant

• Current Assignee: Form Energy, Inc.
• Original Assignee: Fluidic, Inc.
• Inventors: KRISHNAN, Ramkumar, Friesen, Cody A.
• Granted Patent: US 8,911,910 B2
• Time in Patent Office: Days
• US Class Current: 320/134
• CPC Class Codes: H01M 12/04 composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type
• CPC Class Codes: H01M 8/0656 by electrochemical means H01M8/065 takes precedence
• CPC Class Codes: H01M 8/184 Regeneration by electrochemical means
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

One aspect of the present invention provides an electrochemical cell system comprising at least one electrochemical cell configured to be connected to a power supply to recharge the cell. The electrochemical cell system comprises a plurality of electrodes and electrode bodies therein. The electrochemical cell system further comprises a switching system configured to permit modifications of the configuration of anodes and cathodes during charging of the electrochemical cell, and a controller configured to control the switching system. The controller is configured to selectively apply the electrical current to a different number of said electrode bodies based on at least one input parameter so as to adjust a rate and density of the growth of the electrodeposited metal fuel

Claims

1. An electrochemical cell comprising:

a fuel electrode comprising a series of permeable electrode bodies arranged in spaced apart relation;

an oxidant electrode spaced apart from the fuel electrode;

a charging electrode selected from the group consisting of (a) the oxidant electrode, (b) a third electrode spaced from the fuel electrode and the oxidant electrode, and (c) a portion of the fuel electrode;

an ionically conductive medium contacting the electrodes;

a controller coupled to a plurality of the electrode bodies of the fuel electrode, said controller being configured to apply an electrical current between the charging electrode and at least one of the permeable electrode bodies with the charging electrode functioning as an anode and the at least one permeable electrode body functioning as a cathode, such that reducible metal fuel ions in the ionically conductive medium are reduced and electrodeposited as metal fuel in oxidizable form on the at least one permeable electrode body, so that said electrodeposition causes growth of the metal fuel among the permeable electrode bodies with the electrodeposited metal fuel establishing an electrical connection between the permeable electrode bodies,

wherein said controller is configured to selectively apply the electrical current to a different number of said permeable electrode bodies, each functioning as a cathode, based on at least one input parameter so as to adjust a rate and density of the growth of the electrodeposited metal fuel.

2. An electrochemical cell according to claim 1, wherein said controller is configured to select between:

(1) a higher density progressive growth mode wherein the electrical current is applied to a terminal one of the permeable electrode bodies with the charging electrode functioning as the anode and the terminal electrode body functioning as the cathode such that the reducible metal fuel ions are reduced and electrodeposited as metal fuel in oxidizable form on the terminal permeable electrode body, said electrodeposition causing growth of the metal fuel among the permeable electrode bodies such that the electrodeposited metal fuel establishes an electrical connection between the terminal electrode body and each subsequent permeable electrode body with said reduction and deposition occurring on each subsequent permeable electrode body upon establishment of said electrical connection; and

(2) a higher rate growth mode wherein the electrical current is applied simultaneously to a plurality of said electrode bodies with the charging electrode functioning as the anode and each of the plurality of electrode bodies functioning as cathodes such that the reducible metal fuel ions are reduced and electrodeposited as metal fuel in oxidizable form on the terminal permeable electrode body, said electrodeposition causing growth of the metal fuel among the permeable electrode bodies.

3. An electrochemical cell according to claim 2, wherein the controller is configured to apply the electrical current in the higher rate growth mode simultaneously to all the electrode bodies.

4. An electrochemical cell according to claim 2, wherein the controller is configured to apply the electrical current in the higher rate growth mode simultaneously to less than all the electrode bodies.

5. An electrochemical cell according to claim 1, wherein said controller is configured to vary the number of electrode bodies to which the electrical current is applied while performing a recharging operation.

6. An electrochemical cell according to claim 1, wherein the controller is coupled to a sensor that senses a condition of the electrochemical cell, and wherein the input parameter is input by the sensor.

7. An electrochemical cell according to claim 1, wherein the input parameter is input via a user input.

8. An electrochemical cell according to claim 1, wherein the input parameter is a limit parameter and wherein the controller is further configured to compare a cell property to the limit parameter.

9. An electrochemical cell according to claim 8, wherein the cell property is a voltage, a capacity, an impedance between electrodes, a slope of electrode voltages, a current, a resistance to a sensing electrode, or a shorting to the charging electrode.

10. An electrochemical cell according to claim 1, wherein the ionically conductive medium is an electrolyte.

11. An electrochemical cell according to claim 1, further comprising a plurality of switches operatively coupled between the controller and the plurality of electrode bodies, wherein the controller is configured to control an open state and a closed state for each of the plurality of switches, to selectively apply the electrical current to some of the plurality of electrode bodies.

12. An electrochemical cell according to claim 2, wherein in the higher rate growth mode, the electrical current is applied simultaneously to the plurality of electrode bodies such that the charging electrode comprises some of the plurality of electrode bodies functioning as anodes and the fuel electrode comprises some of the plurality of electrode bodies functioning as cathodes, and wherein each of the plurality of electrode bodies functioning as cathodes are separated from one another by the plurality of electrode bodies functioning as anodes.

13. An electrochemical cell according to claim 1, wherein the controller is a charge/discharge controller.

14. An electrochemical cell according to claim 2, wherein the controller is a charge/discharge controller.

15. An electrochemical cell according to claim 6, wherein the controller is a charge/discharge controller.

16. An electrochemical cell according to claim 8, wherein the controller is a charge/discharge controller.

17. An electrochemical cell according to claim 12, wherein the controller is a charge/discharge controller.

18. A method of recharging an electrochemical cell, wherein the electrochemical cell comprises:

a fuel electrode comprising a series of permeable electrode bodies arranged in spaced apart relation;

an oxidant electrode spaced apart from the fuel electrode;

a charging electrode selected from the group consisting of (a) the oxidant electrode, (b) a third electrode spaced from the fuel electrode and the oxidant electrode, and (c) a portion of the fuel electrode;

an ionically conductive medium contacting the electrodes;

a controller coupled to a plurality of the electrode bodies of the fuel electrode, said controller being configured to apply an electrical current between the charging electrode and at least one of the permeable electrode bodies with the charging electrode functioning as an anode and the at least one permeable electrode body functioning as a cathode, such that reducible metal fuel ions in the ionically conductive medium are reduced and electrodeposited as metal fuel in oxidizable form on the at least one permeable electrode body, so that said electrodeposition causes growth of the metal fuel among the permeable electrode bodies with the electrodeposited metal fuel establishing an electrical connection between the permeable electrode bodies,

wherein said controller is configured to selectively apply the electrical current to a different number of said permeable electrode bodies based on at least one input parameter so as to adjust a rate and density of the growth of the electrodeposited metal fuel;

the method comprising;

selecting, based on the at least one input parameter, between a higher density progressive growth mode and a higher rate growth mode;

charging the electrochemical cell based on the selected one of the higher density progressive charge mode and the higher rate growth mode;

wherein, in the higher density progressive growth mode, said charging comprises;

applying the electrical current to a terminal one of the permeable electrode bodies, with the charging electrode functioning as the anode and the terminal electrode body functioning as the cathode, such that the reducible metal fuel ions are reduced and electrodeposited as metal fuel in oxidizable form on the terminal permeable electrode body, said electrodeposition causing growth of the metal fuel among the permeable electrode bodies such that the electrodeposited metal fuel establishes an electrical connection between the terminal electrode body and each subsequent permeable electrode body with said reduction and deposition occurring on each subsequent permeable electrode body upon establishment of said electrical connection; and

wherein, in the higher rate growth mode, said charging comprises;

applying the electrical current simultaneously to a plurality of said electrode bodies, with the charging electrode functioning as the anode and each of the plurality of electrode bodies functioning as cathodes, such that the reducible metal fuel ions are reduced and electrodeposited as metal fuel in oxidizable form on the terminal permeable electrode body, said electrodeposition causing growth of the metal fuel among the permeable electrode bodies; and

disconnecting the electrical current to discontinue the charging.

19. A method of recharging the electrochemical cell according to claim 18, wherein, in the higher rate growth mode, the charging electrode comprises one or more of the plurality of electrode bodies adjacent to the plurality of the electrode bodies functioning as cathodes

20. A method of recharging the electrochemical cell according to claim 18, wherein, in the higher rate growth mode, said charging further comprises performing continuity testing on one or more of the plurality of electrode bodies to determine electrical connections formed between any of the electrode bodies functioning as cathodes and any of the charging electrode;

and disconnecting any of the electrode bodies.

21. A method of recharging the electrochemical cell according to claim 18, wherein the at least one input parameter comprises measurements obtained by a sensor associated with the electrochemical cell, and wherein the method further comprises sensing, with the sensor, the measurements of the electrochemical cell.

22. A method of recharging the electrochemical cell according to claim 18, wherein the at least one input parameter comprises a user selection of the higher density progressive charge mode or the higher rate growth mode, input via a user input, wherein the method further comprises receiving a user selection via the user input.

23. A method of recharging the electrochemical cell according to claim 18, wherein the at least one input parameter is a limit parameter and wherein the controller is further configured to compare a cell property to the limit parameter to perform said selecting.

24. A method of recharging the electrochemical cell according to claim 18, wherein, in the higher rate growth mode, said charging comprises applying the electrical current simultaneously to all of the electrode bodies.

25. A method of recharging the electrochemical cell according to claim 18, wherein, in the higher rate growth mode, said charging comprises applying the electrical current simultaneously to less than all of the electrode bodies.

26. A method of recharging the electrochemical cell according to claim 18, wherein said charging comprises varying, with the controller, the number of electrode bodies to which the electrical current is applied while performing a recharging operation.

27. A method of recharging the electrochemical cell according to claim 18, wherein the ionically conductive medium of the electrochemical cell is an electrolyte.

28. A method of recharging the electrochemical cell according to claim 18, wherein the electrochemical cell further comprises a plurality of switches operatively coupled between the controller and the plurality of electrode bodies, and wherein said charging comprises controlling an open state and a closed state for each of the plurality of switches with the controller, to selectively apply the electrical current to some of the plurality of electrode bodies.

29. A method of recharging the electrochemical cell according to claim 18, wherein in the higher rate growth mode, said charging comprises applying the electrical current simultaneously to the plurality of electrode bodies such that the charging electrode comprises some of the plurality of electrode bodies functioning as anodes and the fuel electrode comprises some of the plurality of electrode bodies functioning as cathodes, and wherein each of the plurality of electrode bodies functioning as cathodes are separated from one another by the plurality of electrode bodies functioning as anodes.

30. A method according to claim 18, wherein the controller is a charge/discharge controller.

31. A method according to claim 21, wherein the controller is a charge/discharge controller.

32. A method according to claim 23, wherein the controller is a charge/discharge controller.

33. A method according to claim 28, wherein the controller is a charge/discharge controller.