Metal-air fuel cell battery system employing metal-fuel cards

• US 6,544,678 B2
• Filed: 01/11/2001
• Issued: 04/08/2003
• Est. Priority Date: 10/06/1997
• Status: Expired due to Fees

• Current Assignee: Reveo, Inc.
• Original Assignee: Reveo, Inc.
• Inventors: Yao, Wayne, Chang, Yuen-Ming, Tsai, Tsepin, Faris, Sadeg M.
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US09/760,003
• Publication Number:
  US 20010023036A1
• Time in Patent Office: 817 Days
• Field of Search: 429/25, 429/27, 429/68, 429/127, 429/208, 429/238
• US Class Current: 429/404
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 50/72 Constructional details of fuel cells specially adapted for electric vehicles
• CPC Class Codes: B60L 58/33 by cooling
• CPC Class Codes: H01M 10/4214 Arrangements for moving electrodes or electrolyte
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 12/06 with one metallic and one gaseous electrode
• CPC Class Codes: H01M 12/08 composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
• CPC Class Codes: H01M 2004/024 Insertable electrodes
• CPC Class Codes: H01M 2300/0085 Immobilising or gelification of electrolyte
• CPC Class Codes: H01M 4/42 Alloys based on zinc
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: H01M 6/5011 for several cells simultaneously or successively
• CPC Class Codes: H01M 8/184 Regeneration by electrochemical means
• CPC Class Codes: H01M 8/186 by electrolytic decomposition of the electrolytic solution or the formed water product
• CPC Class Codes: H01M 8/22 Fuel cells in which the fuel is based on materials comprising carbon or oxygen or hydrogen and other elements; Fuel cells in which the fuel is based on materials comprising only elements other than carbon, oxygen or hydrogen
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

Improved metal-air fuel cell battery systems having metal-fuel realized in the form of metal-fuel tape cartridges and metal-fuel cards, which can be either manually or automatically inserted within the power generation bay of the system. In order to produce a range of output voltages, the metal-fuel tape has a plurality of electrically-isolated metal-fuel tracks and the metal-fuel cards have a plurality of electrically-isolated metal-fuel strips. An output voltage configuration subsystem is provided for configuring the voltages produced by the individual cells to produce a desired output. A subsystem is provided for detecting oxide formation on the metal-fuel tracks and strips so that only metal-fuel that has been oxidized is reduced during recharging operations. A subsystem is also provided for controlling the flow of oxygen into the power generation head in order to control the power output from the system.

Claims

1. A metal-air fuel cell battery (FCB) system, comprising:

first and second output supply terminals for supplying electrical power to an electrical load at an output voltage;

an electrically-conductive cathode element pervious to oxygen;

an ionically-conductive medium for providing a source of ions at said electrically-conductive cathode element;

a cathode support structure for supporting an said electrically-conductive cathode element;

at least one metal-fuel element, functioning as an electrically conductive anode element, with said ionically-conductive medium disposed between said metal-fuel element and said electrically-conductive cathode element;

an electrically-conductive anode-contacting element for establishing electrical contact with said metal-fuel element during operation of said metal-air fuel cell battery system;

an anode contacting structure for supporting said electrically-conductive anode-contacting element in electrical contact with said metal-fuel element;

a first electrically-conductive pathway from said electrically conductive cathode element to said first output power supply terminal;

a second electrically-conductive pathway from said electrically conductive anode element to said second output power supply terminal; and

means for sensing the partial oxygen pressure (PO₂) within said electrically-conductive cathode element, and producing an electrical signal indicative thereof,

wherein said electrically conductive cathode element is at least partially disposed within a recess in said cathode support structure.

2. The metal-air fuel cell battery system of claim 1, wherein said cathode support structure has a recess for supporting said electrically-conductive cathode element.

3. The metal-air fuel cell battery system of claim 1, wherein said ionically-conductive medium comprises an electrolyte-impregnated pad disposed over said electrically-conductive cathode element within said recess.

4. The metal-air fuel cell battery system of claim 1, wherein said cathode element comprises an electrically-conductive mesh substrate to which said first electrically-conductive pathway is electrically connected, and porous carbon material adhered to said electrically-conductive mesh substrate.

5. The metal-air fuel cell battery system of claim 4, wherein said electrically-conductive mesh substrate is made of nickel, and said electrically-conductive anode element is made of zinc.

6. The metal-air fuel cell battery system of claim 5, wherein said electically-conductive cathode element further comprises a catalyst material embodied within said porous carbon material.

7. The metal-air fuel cell battery system of claim 1, which further comprises a plurality of air holes formed in a surface of said recess to permit ambient air to flow through said electrically-conductive cathode element.

8. The metal-air fuel cell battery system of claim 7, which further comprises air-throttling means associated with said cathode support structure, for throttling the flow of ambient air through said plurality of air holes.

9. The metal-air fuel cell battery system of claim 1, which further comprises means for sensing the electrical current flowing into said electrical load, and means for sensing the electrical voltage across said electrical load.

10. The metal-air fuel cell battery system of claim 8, which further comprises a system controller for controlling said air-throttling means.

11. The metal-air fuel cell battery system of claim 10, wherein said system contoller comprises a microcontroller.

12. The metal-air fuel cell battery system of claim 1, which further comprises a metal fuel support structure for supporting said metal fuel element.

13. The metal-air fuel cell battery system of claim 1, which further comprises means for transporting said metal-fuel element relative to said electrically-conductive cathode element.

14. The metal-air fuel cell battery system of claim 12, which further comprises means for transporting said anode contacting support structure relative to said element-fuel element.

15. The metal-air fuel cell battery system of claim 12, which further comprises means for transporting said metal-fuel support structure and said anode contacting support structure in response to a predetermined condition.

16. A metal-air fuel cell battery (FCB) system, comprising:

first and second output supply terminals for supplying electrical power to an electrical load at an output voltage;

an electrically-conductive cathode element pervious to oxygen;

an ionically-conductive medium for providing a source of ions at said electrically-conductive cathode element;

a cathode support structure for supporting an said electrically-conductive cathode element;

at least one metal-fuel element, functioning as an electrically-conductive anode element, with said ionically-conductive medium disposed between said metal-fuel element and said electrically-conductive cathode element;

an electrically-conductive anode-contacting element for establishing electrical contact with said metal-fuel element during operation of said metal-air fuel cell battery system;

an anode contacting structure for supporting said electrically-conductive anode-contacting element in electrical contact with said metal-fuel element;

a first electrically-conductive pathway from said electrically conductive cathode element to said first output power supply terminal;

a second electrically-conductive pathway from said electrically conductive anode element to said second output power supply terminal;

a metal fuel support structure for supporting said metal fuel element; and

means for transporting said anode contacting support structure relative to said metal-fuel element,

wherein said electrically conductive cathode element is at least partially disposed within a recess in said cathode support structure.

17. The metal-air fuel cell battery system of claim 16, wherein said cathode support structure has a recess for supporting said electrically-conductive cathode element.

18. The metal-air fuel cell battery system of claim 16, wherein said ionically-conductive medium comprises an electrolyte-impregnated pad disposed over said electrically-conductive cathode element within said recess.

19. The metal-air fuel cell battery system of claim 16, wherein said cathode element comprises an electrically-conductive mesh substrate to which said first electrically-conductive pathway is electrically connected, and porous carbon material adhered to said electrically-conductive mesh substrate.

20. The metal-air fuel cell battery system of claim 19, wherein said electrically-conductive mesh substrate is made of nickel, and said electrically-conductive anode element is made of zinc.

21. The metal-air fuel cell battery system of claim 20, wherein said electically-conductive cathode element further comprises a catalyst embodied within said porous carbon material.

22. The metal-air fuel cell battery system of claim 16, which further comprises a plurality of air holes formed in a surface of said recess to permit ambient air to flow through said electrically-conductive cathode element.

23. The metal-air fuel cell battery system of claim 22, which further comprises air-throttling means associated with said cathode support structure, for throttling the flow of ambient air through said plurality of air holes.

24. The metal-air fuel cell battery system of claim 16, which further comprises means for sensing the partial oxygen pressure (PO₂) within said electrically-conductive cathode element, and producing an electrical signal indicative thereof.

25. The metal-air fuel cell battery system of claim 16, which further comprises

means for sensing the electrical current flowing into said electrical load, and

means for sensing the electrical voltage across said electrical load.

26. The metal-air fuel cell battery system of claim 23, which further comprises a system controller for controlling said air-throttling means.

27. The metal-air fuel cell battery system of claim 26, wherein said system controller comprises a microcntroller.

28. The metal-air fuel cell battery system of claim 16, which further comprises means for transporting said metal-fuel element relative to said electrically-conductive cathode element.

29. A metal-air fuel cell battery (FCB) system, comprising:

first and second output supply terminals for supplying electrical power to an electrical load at an output voltage;

an electrically-conductive cathode element pervious to oxygen;

an ionically-conductive medium for providing a source of ions at said electrically-conductive cathode element;

a cathode support structure for supporting an said electrically-conductive cathode element;

at least one metal-fuel element, functioning as an electrically-conductive element, with said ionically-conductive medium disposed between said metal-fuel element and said electrically-conductive cathode element;

an electrically-conductive anode-contacting element for establishing electrical contact with said metal-fuel element during operation of said metal-air fuel cell battery system;

an anode contacting structure for supporting said electrically-conductive anode-contacting element in electrical contact with said metal-fuel element;

a first electrically-conductive pathway from said electrically conductive cathode element to said first output power supply terminal;

a second electrically-conductive pathway from said electrically conductive anode element to said second output power supply terminal;

a metal fuel support structure for supporting said metal fuel element; and

means for transporting said metal-fuel support structure and said anode contacting support structure in response to a predetermined condition,

wherein said electrically conductive cathode element is at least partially disposed within a recess in said cathode support structure.

30. The metal-air fuel cell battery system of claim 29, wherein said cathode support structure has a recess for supporting said electrically-conductive cathode element.

31. The metal-air fuel cell battery system of claim 29, wherein said ionically-conductive medium comprises an electrolyte-impregnated pad disposed over said electrically-conductive cathode element within said recess.

32. The metal-air fuel cell battery system of claim 29, wherein said cathode element comprises an electrically-conductive mesh substrate to which said first electrically-conductive pathway is electrically connected, and porous carbon material adhered to said electrically-conductive mesh substrate.

33. The metal-air fuel cell battery system of claim 32 wherein said electrically-conductive mesh substrate is made of nickel, and said electrically-conductive anode element is made of zinc.

34. The metal-air fuel cell battery system of claim 33, wherein said electrically-conductive cathode element further comprises a catalyst material embodied within said porous carbon material.

35. The metal-air fuel cell battery system of claim 29, which further comprises a plurality of air holes formed in a surface of said recess to permit ambient air to flow through said electrically-conductive cathode element.

36. The metal-air fuel cell battery system of claim 35, which further comprises air-throttling means associated with said cathode support structure, for throttling the flow of ambient air through said plurality of air holes.

37. The metal-air fuel cell battery system of claim 29, which further comprises means for sensing the partial oxygen pressure (PO₂) within said electrically-conductive cathode element, and producing an electrical signal indicative thereof.

38. The metal-air fuel cell battery system of claim 29, which further comprises

means for sensing the electrical current flowing into said electrical load, and

means for sensing the electrical voltage across said electrical load.

39. The metal-air fuel cell battery system of claim 36, which further comprises a system controller for controlling said air-throttling means.

40. The metal-air fuel cell battery system of claim 39, wherein said system controller comprises a microcontroller.

41. The metal-air fuel cell battery system of claim 29, which further comprises means for transporting said metal-fuel element relative to said electrically-conductive cathode element.