Air mover for a battery utilizing a variable volume enclosure

• US 6,436,564 B1
• Filed: 12/18/1998
• Issued: 08/20/2002
• Est. Priority Date: 12/18/1998
• Status: Expired due to Term

• Current Assignee: Duracell U.S. Operations, Inc. (Berkshire Hathaway Incorporated)
• Original Assignee: AER Energy Resources, Inc.
• Inventors: Witzigreuter, John D., Young, Jeffrey E.
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US09/216,118
• Time in Patent Office: 1,341 Days
• Field of Search: 429/7, 429/24, 429/27, 429/62, 429/82, 383/2, 383/33, 383/45, 383/103, 383/121.1
• US Class Current: 429/407
• CPC Class Codes: H01M 12/06 with one metallic and one gaseous electrode

Abstract

The metal-air battery includes an air mover mechanism located in the cathode plenum space of one or more metal-air cells. The air mover is an enclosure isolating the air cathode, with a mechanism for expanding and contracting the volume of the enclosure to move air in and out of the enclosure. Prismatic and cylindrical batteries incorporating the invention are described.

Claims

1. A metal air power supply, comprising:

a variable volume enclosure isolating one or more air electrodes from ambient air except through one or more passageways; and

means for varying the volume of said enclosure such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting.

2. The power supply of claim 1, wherein said one or more passageways are shaped to be operative to restrict air flow into and out of said enclosure while said passageways are unsealed and the volume of said enclosure is static.

3. The power supply of claim 1, wherein said variable volume enclosure comprises:

a rigid plate mounted for movement toward and away from said air electrode; and

a deformable wall extending from said rigid plate to a frame member surrounding said air electrode, so as to isolate a volume between said rigid plate and said air electrode from ambient air except through said one or more passageways.

4. The power supply of claim 1, wherein said variable volume enclosure comprises a collapsible bag mounted onto a frame member surrounding said air electrode, so as to isolate a volume within said collapsible bag from ambient air except through said one or more passageways.

5. The power supply of claim 4, wherein said means for varying the volume of said enclosure comprises means for at least partly collapsing said collapsible bag and means for alternately expanding said collapsible bag.

6. An air moving device for supplying ambient air to an air electrode of a metal air power supply, comprising:

a variable volume enclosure for isolating said electrode from ambient air except through one or more passageways, wherein said variable volume enclosure comprises;

a rigid plate mounted for movement toward and away from said electrode while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, and

a deformable wall extending from said rigid plate to a frame member for surrounding said electrode so as to isolate a volume between said rigid plate and said electrode from ambient air except through said one or more passageways, while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways; and

means for varying the volume of said enclosure while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting, wherein said means for varying the volume of said enclosure comprises means for alternately moving said rigid plate toward said electrode and away from said electrode while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, and wherein said means for alternately moving said rigid plate toward said electrode and away from said electrode comprises;

means for selectively moving said rigid plate away from said electrode while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways;

a first line extending between said rigid plate and a fixed member positioned below said rigid plate; and

means for selectively pulling said rigid plate toward said fixed member using said first line.

7. The air moving device of claim 6 in combination with said metal air power supply, wherein said metal air power supply includes an outer casing extending above said rigid plate and wherein said means for selectively moving said rigid plate away from said electrode comprises:

a second line extending between said rigid plate and said outer casing; and

means for selectively pulling said rigid plate toward said outer casing using said second line.

8. The combination of claim 7, wherein:

said second line comprises a shape memory alloy wire; and

said means for selectively pulling said rigid plate toward said outer casing using said second line comprises said electrical circuit, said electric circuit being connected to said shape memory alloy wire and operative to selectively direct an electric current through said shape memory alloy wire so as to cause said shape memory alloy wire to contract.

9. The combination of claim 8, wherein:

said first line comprises a shape memory alloy wire; and

said means for selectively pulling said rigid plate toward said fixed member using said second line comprises said electrical circuit, said electric circuit being connected to said shape memory alloy wire and operative to selectively direct an electric current through said shape memory alloy wire so as to cause said shape memory alloy wire to contact.

10. The combination of claim 9, wherein said electric circuit draws power from said metal air power supply.

11. The combination of claim 7, wherein said means for selectively pulling said rigid plate toward said fixed member using said first line comprises a winch operative to reel in said first line so as to pull said rigid plate toward said fixed member.

12. The combination of claim 11, wherein said means for selectively pulling said rigid plate toward said outer casing using said second line comprises a second winch operative to reel in said second line so as to pull said rigid plate toward said outer casing.

13. The combination of claim 7, wherein said first line extends between said rigid plate and said fixed member with a substantial component parallel to said electrode and said means for selectively pulling said rigid plate toward said fixed member includes a cam surface and a cam follower positioned such that the movement of said rigid plate responsive to the movement of said first line is transposed into a direction substantially perpendicular to said electrode.

14. The combination of claim 13, wherein said second line extends between said rigid plate and said outer casing with a substantial component parallel to said electrode and said means for selectively pulling said rigid plate toward said outer casing includes a cam surface and a cam follower positioned such that the movement of said rigid plate responsive to the movement of said second line is transposed into a direction substantially perpendicular to said electrode.

15. The air moving device of claim 6, wherein:

said means for selectively moving said rigid plate away from said electrode comprises one or more spring members positioned between said rigid plate and said electrode operative to urge said plate away from said electrode; and

said means for selectively pulling said rigid plate toward said fixed member using said first line comprises means for selectively pulling said rigid plate from an initial position toward said fixed member against the force of said spring member using said first line.

16. The air moving device of claim 15, wherein said first line comprises a shape memory alloy wire and said means for selectively pulling said rigid plate from an initial position toward said fixed member against the force of said spring member using said first line comprises an electrical circuit, said electric circuit being connected to said shape memory alloy wire and operative to selectively direct an electric current through said shape memory alloy wire so as to cause said shape memory alloy wire to contract.

17. The air moving device of claim 15, wherein said means for selectively pulling said rigid plate from an initial position toward said fixed member against the force of said spring member using said first line comprises a winch operative to reel in said first line so as to pull said rigid plate toward said fixed member.

18. An air moving device for supplying ambient air to an air electrode of a metal air power supply, comprising:

a variable volume enclosure for isolating said electrode from ambient air except through one or more passageways, wherein said variable volume enclosure comprises;

a rigid plate mounted for movement toward and away from said electrode while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, and

a deformable wall extending from said rigid plate to a frame member for surrounding said electrode so as to isolate a volume between said rigid plate and said electrode from ambient air except through said one or more passageways, while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways; and

means for varying the volume of said enclosure while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting, wherein said means for varying the volume of said enclosure comprises means for alternately moving said rigid plate toward said electrode and away from said electrode while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, and

wherein the air moving device is in combination with said metal air power supply, wherein said metal air power supply includes means for preventing outward deformation of said deformable wall such that the volume of said variable volume enclosure decreases as said rigid plate moves towards said electrode.

19. The combination of claim 18, wherein said means for preventing outward deformation of said deformable wall comprises one or more retaining structures positioned to prevent outward deformation of said deformable wall.

20. The combination claim 19, wherein said one or more retaining structures comprise walls positioned outside said variable volume enclosure.

21. A metal air power supply, comprising:

a variable volume enclosure isolating one or more air electrodes from ambient air except through one or more passageways, said enclosure comprising a rigid plate mounted for movement toward and away from said electrode while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through one or more passageways, and a deformable wall extending from said rigid plate to a frame member for surrounding said electrode; and

a linear actuator connected to said plate and operative to move said plate to vary the volume of said enclosure while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting, wherein said linear actuator is powered by electrical current from one or more cells of the power supply.

22. A cylindrical metal-air power supply, comprising:

a cylindrical air cathode;

an anode and electrolyte positioned within said cathode;

an enclosure around said air cathode, isolating said cathode from ambient air except through an air conduit; and

means for alternately contracting and expanding the volume of said enclosure to move air in and out of said enclosure through said air conduit.

23. A cylindrical metal-air power supply, comprising:

a conductive cylindrical case body including a cylindrical case wall, a case bottom, and an anode current collector extending into said case body from said case bottom;

a mixture of anode metal and electrolyte within said case body in contact with said anode current collector;

an air cathode positioned around said mixture and spaced inwardly from an inner surface of said cylindrical case wall, a cylindrical cathode air plenum being formed inside said cylindrical case wall;

a case cover including a terminal electrically connected to a cathode current collector of said air cathode and insulated from said conductive case body;

an enclosure within said cathode air plenum around said air cathode;

an air conduit connecting the interior of said enclosure to the atmosphere outside said case; and

means for alternately contracting and expanding the volume of said enclosure within said cathode air plenum to move air in and out of said enclosure through said air conduit.

24. A cylindrical metal-air power supply, comprising:

a conductive cylindrical case body including a cylindrical case wall, a case bottom, and an anode current collector extending into said case body from said case bottom;

a mixture of anode metal and electrolyte within said case body in contact with said anode current collector;

an air cathode positioned around said mixture and spaced inwardly from an inner surface of said cylindrical case wall, a cylindrical cathode air plenum being formed inside said cylindrical case wall;

a case cover including a terminal electrically connected to a cathode current collector of said air cathode and insulated from said conductive case body;

a collapsible bag positioned within said cathode air plenum around said air cathode;

an air conduit connecting the interior of said bag and the atmosphere outside said case; and

means for alternately contracting and expanding said bag within said cathode air plenum to move air in and out of said bag through said air conduit.

25. The metal-air power supply of claim 24, further comprising additional said air conduits between the interior of said bag and the atmosphere outside said case.

26. The metal-air power supply of claim 24, wherein said air conduit comprises a diffusion limiting passageway.

27. The metal-air power supply of claim 24, wherein said means for alternately contracting and expanding said bag comprises:

one or more lines engaging said bag;

means for reducing an initial effective length of said lines to collapse said bag from an initial volume to a smaller volume; and

means for returning said bag to said initial volume.

28. The metal-air power supply of claim 27, wherein said means for returning said bag to said initial volume comprises one or more spring members.

29. The metal-air power supply of claim 28, wherein said one or more lines comprise shape memory alloy wires, and said means for reducing an initial effective length of said lines comprises an electrical circuit connected to supply current through said wires.

30. The metal-air power supply of claim 28, wherein said means for reducing an initial effective length of said lines comprises a winch including a reel operative for winding up said lines.

31. The metal-air power supply of claim 27, wherein

said lines comprise a plurality of shape memory wires retained to said bag;

said means for reducing an initial effective length of said lines comprises an electrical circuit connected to supply current through said wires to shrink an initial diameter thereof; and

said means for returning said bag to said initial volume comprises a plurality of arcuate wire springs retained to said bag.

32. The metal-air power supply of claim 31, wherein said bag comprises a two-ply material defining passageways in which said shape memory alloy wires and said wire springs are captured, said wires and springs moving longitudinally within said passageways.

33. The metal-air power supply of claim 24, wherein said bag extends from an essentially sealed connection to said case body at a base of said anode current collector to cover said air cathode and anode mixture beneath said case cover.

34. A metal air power supply, comprising:

a variable volume enclosure for isolating one or more air electrodes from ambient air except through one or more passageways, wherein said variable volume enclosure comprises;

a rigid plate mounted for movement toward and away from said one or more air electrodes while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, wherein said one or more passageways extend through said rigid plate, and

a deformable wall extending from said rigid plate to a frame member for surrounding said one or more air electrodes so as to isolate a volume between said rigid plate and said one or more air electrodes from ambient air except through said one or more passageways, while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways; and

means for varying the volume of said enclosure while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting, wherein said means for varying the volume of said enclosure is powered by electrical current from one or more cells of the power supply.

35. A metal air power supply, comprising:

a variable volume enclosure for isolating one or more air electrodes from ambient air except through one or more passageways, wherein said variable volume enclosure comprises;

a rigid plate mounted for movement toward and away from said one or more air electrodes while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, and

a deformable wall extending from said rigid plate to a frame member for surrounding said one or more air electrodes so as to isolate a volume between said rigid plate and said one or more air electrodes from ambient air except through said one or more passageways, while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, wherein said one or more passageways extend through said deformable wall; and

means for varying the volume of said enclosure while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting, wherein said means for varying the volume of said enclosure is powered by electrical current from one or more cells of the power supply.

36. A metal air power supply, comprising:

a variable volume enclosure for isolating one or more air electrodes from ambient air except through one or more passageways, wherein said variable volume enclosure comprises;

a rigid plate mounted for movement toward and away from said one or more air electrodes while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, and

a deformable wall extending from said rigid plate to a frame member for surrounding said one or more air electrodes so as to isolate a volume between said rigid plate and said one or more air electrodes from ambient air except through said one or more passageways, while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways; and

means for varying the volume of said enclosure while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting, wherein said means for varying the volume of said enclosure comprises means for alternately moving said rigid plate toward said one or more air electrodes and away from said one or more air electrodes while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, wherein said means for varying the volume of said enclosure is powered by electrical current from one or more cells of the power supply.

37. A metal air power supply, comprising:

a variable volume enclosure isolating one or more air electrodes from ambient air except through one or more passageways, wherein said variable volume enclosure comprises a collapsible bag mounted onto a frame member for surrounding said electrode while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, so as to isolate a volume within said collapsible bag from ambient air except through said one or more passageways, and wherein said one or more passageways extend through said collapsible bag; and

means for varying the volume of said enclosure while said variable volume enclosure is isolating said one or more air electrodes from ambient air except through said one or more passageways, such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting.

38. An air moving device for supplying ambient air to an air electrode of a metal air power supply, comprising:

a variable volume enclosure for isolating said electrode from ambient air except through one or more passageways, wherein said variable volume enclosure comprises a collapsible bag mounted onto a frame member for surrounding said electrode while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, so as to isolate a volume within said collapsible bag from ambient air except through said one or more passageways; and

means for varying the volume of said enclosure while said variable volume enclosure is isolating said electrode from ambient air except through said one or more passageways, such that air is moved into said enclosure through said one or more passageways when the volume of said enclosure is expanding and air is moved out of said enclosure through said one or more passageways when the volume of said enclosure is contracting, wherein said means for varying the volume of said enclosure comprises means for at least partly collapsing said collapsible bag and means for alternately expanding said collapsible bag, and wherein said means for at least partly collapsing said collapsible bag comprises;

one or more first lines engaging said collapsible bag, and

means for selectively shortening an effective length of said first line or lines.

39. The air moving device of claim 38, wherein said means for alternately expanding said collapsible bag comprises:

one or more second lines engaging said collapsible bag; and

means for selectively shortening an effective length of said second line or lines.

40. The air moving device of claim 39, wherein:

said one or more first lines comprise shape memory alloy wires; and

said means for selectively shortening an effective length of said first line or lines comprises an electrical circuit, said electric circuit being connected to said shape memory alloy wires and operative to selectively direct an electric current through said shape memory alloy wires so as to cause said shape memory alloy wires to contract.

41. The air moving device of claim 40, wherein:

said one or more second lines comprise shape memory alloy wires; and

said means for selectively shortening an effective length of said second line or lines comprises an electrical circuit, said electric circuit being connected to said shape memory alloy wires and operative to selectively direct an electric current through said shape memory alloy wires so as to cause said shape memory alloy wires to contract.

42. The air moving device of claim 39, wherein said means for selectively shortening an effective length of said first line or lines comprises one or more winches operative to reel in said first line or lines.

43. The air moving device of claim 42, wherein said means for selectively shortening an effective length of said second line or lines comprises one or more winches operative to reel in said second line or lines.

44. The air moving device of claim 38, wherein means for alternately expanding said collapsible bag comprises one or more spring members positioned within said collapsible bag and operative to urge said collapsible bag away from said electrode while said variable volume enclosure is isolating said electrode from ambient air except through one or more passageways.