Appliance with refuelable and rechargeable metal-air fuel cell battery power supply unit integrated therein

• US 6,558,829 B1
• Filed: 10/24/2000
• Issued: 05/06/2003
• Est. Priority Date: 10/06/1997
• Status: Expired due to Fees

• Current Assignee: Reveo, Inc.
• Original Assignee: Reveo, Inc.
• Inventors: Faris, Sadeg M., Tsai, Tsepin
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US09/695,697
• Time in Patent Office: 924 Days
• Field of Search: 429/27, 429/22, 320/101
• US Class Current: 429/404
• CPC Class Codes: H01M 10/42 Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• 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 6/42 Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: H01M 8/04 Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A device/system having an integrated refuelable and rechargable metal-air FCB based power supply unit for generating and providing electrical power to at least one electrical-energy-consuming load device disposed therein. An external power source is used to recharge the metal-air FCB subsystems embodied therein. A control subsystem automatically transitions between discharging mode (wherein at least one metal-air FCB subsystem supplies electrical power to the electrical power-consuming load device) and a recharging mode (wherein the external power source is electrically coupled to at least one metal-air FCB subsystem to thereby recharge the metal-air FCB subsystem(s). The metal-air FCB subsystem(s) are refueled by manually loading and unloading metal-fuel from the metal-air FCB subsystem(s). Preferably, electrical power provided to the at least one electrical power-consuming load device is supplied solely by electrical power generated by discharging metal-fuel in the metal-air fuel cell battery subsystem(s). In addition, the metal-air FCB subsystem(s) preferably has a modular architecture that enable flexible and user-friendly operations in loading of metal-fuel, unloading of consumed metal-fuel, replacement of the ionic-conducting medium, and replacement of the cathode.

Claims

1. An appliance for use with an external power source, the appliance comprising:

a system housing with at least one electrical-energy-consuming load device disposed therein;

a refuelable and rechargeable power supply unit integrated into the system housing, the power supply unit comprising;

a metal-air fuel cell battery subsystem comprising at least one metal-air fuel cell capable of generating and storing electrical power, wherein consumed metal-fuel is unloaded from and metal fuel loaded into the metal-air fuel cell battery subsystem to thereby refuel the metal-air fuel cell battery subsystem; and

a controller that enables electrical connection from the metal-air fuel cell battery subsystem to the electrical power-consuming load device in a discharging mode to thereby supply electrical power to the electrical power-consuming load device, that enables electrical connection from the external power source to the metal-air fuel cell battery subsystem in a recharging mode to thereby recharge the metal-air fuel cell battery subsystem, and that identifies at least a portion of consumed metal-fuel to be refueled.

2. The appliance of claim 1, wherein electrical power provided to the electrical power-consuming load device is supplied solely by the metal-air fuel cell battery subsystem.

3. The appliance of claim 2, wherein electrical power provided to the electrical power-consuming load device is supplied solely by electrical power generated by the metal-air fuel cell battery subsystem operating in discharging mode.

4. The appliance of claim 1, further comprising an input power bus and output power bus both coupled to the metal-air fuel cell battery subsystem, wherein the input power bus provides an electrical connection from the external power source to the metal-fuel cell battery subsystem in the recharging mode to thereby recharge the metal-air fuel cell battery system, and wherein the output power bus provides an electrical connection from the metal-fuel cell battery subsystem to said electrical power-consuming load device in the discharging mode to thereby provide electrical power to the electrical power-consuming load device.

5. The appliance of claim 4, wherein the metal-air fuel cell battery subsystem comprises a network of metal-air fuel cell modules each comprising a plurality of metal-air fuel cells, wherein the network of metal-air fuel cell modules includes a first set of modules distinct from a second set of modules;

and wherein said controller operates the first set of modules in discharging mode to thereby supply electrical power from the first set of modules to said electrical power-consuming load device via the output power bus concurrent with operation of the second set of modules in recharging mode to thereby recharge the second set of modules with electrical power supplied from the external power source via the input power bus.

6. The appliance of claim 4, wherein the metal-air fuel cell battery subsystem comprises a plurality of metal-air fuel cells including a first set of metal-air fuel cells distinct from a second set of fuel cells;

and said controller operates the first set of fuel cells in discharging mode to thereby supply electrical power from the first set of fuel cells to said electrical power-consuming load device via the output power bus concurrent with operation of the second set of fuel cells in recharging mode to thereby recharge the second set of fuel cells with electrical power supplied from the external power source via the input power bus.

7. The appliance of claim 1, wherein the system housing includes recesses into which metal-fuel is manually loaded into the metal-air fuel cell battery subsystem and from which consumed metal-fuel is manually unloaded from the metal-air fuel cell battery subsystem.

8. The appliance of claim 7, wherein the metal-fuel is disposed on a card structure that is manually loaded into and unloaded from the recesses.

9. The appliance of claim 8, wherein the card structure comprises a plurality of distinct metal-fuel elements integrated therein.

10. The appliance of claim 7, wherein the metal-fuel is disposed in a cartridge that is that is manually loaded into and unloaded from the recesses.

11. The appliance of claim 10, wherein the cartridge holds metal-fuel tape.

12. The appliance of claim 10, wherein the cartridge holds sheets of metal-fuel.

13. The appliance of claim 10, wherein the cartridge stores a paste including anode material particles suspended in a liquid ionically-conducting medium.

14. The appliance of claim 1, wherein the appliance comprises a computer processing apparatus.

15. The appliance of claim 1, wherein the appliance comprises a portable electronic device.

16. The appliance of claim 15, wherein the portable electronic device is one of the following:

radio, disc player, other portable music playing devices, camcorder, other video playing/recording devices, telephone, PDA, other communication devices.

17. The appliance of claim 1, where the appliance comprises one of the following:

television, audio equipment, washing machine, refrigerator, freezer, oven, stove, furnace, air conditioner.

18. The appliance of claim 1, wherein the appliance comprises an electrically-powered tool.

19. The appliance of claim 1, wherein the external power source comprises a public electric utility grid.

20. The appliance of claim 1, wherein the external power source derives energy from a public utility grid.

21. The appliance of claim 1, wherein the external power source comprises a wind-driven power generator.

22. The appliance of claim 1, wherein the external power source comprises a generator that derives energy from solar energy.

23. The appliance of claim 4, further comprising an switching network, coupled to the input power bus, the output power bus, and the power terminals of a plurality of metal-air fuel cell battery subsystems that operates, in response to control signals from said controller, to:

selectively couple the input power bus to the power terminals of one or more of the plurality of metal-air fuel cell battery subsystems;

to selectively couple the output power bus to the power terminals of one or more of the plurality of metal-air fuel cell battery subsystems; and

to selectively couple together the power terminals of two or more of the metal-air fuel cell battery subsystems.

24. A method for operating an appliance comprising a system housing with at least one electrical-energy-consuming load device disposed therein, the method comprising the steps of:

providing a power supply unit integrated into the system housing, the power supply unit having a metal-air fuel cell battery subsystem disposed within a modular housing, the metal-air fuel cell battery subsystem comprising at least one metal-air fuel cell capable of generating and storing electrical power, and wherein consumed metal-fuel is unloaded from and metal-fuel is loaded into the metal-air fuel cell battery subsystem to thereby refuel the metal-air fuel cell battery subsystem; and

providing a control subsystem that operates in a discharging mode to enable electrical connection from the metal-fuel cell battery subsystem to the electrical power-consuming load device to thereby supply electrical power to the electrical power-consuming load device, that operates in a recharging mode to enable electrical connection from an external power source to the metal-fuel cell battery to thereby recharge the metal-air fuel cell battery subsystem, and that identifies at least a portion of consumed metal-fuel to be refueled.

25. The method of claim 24, wherein electrical power provided to the electrical power-consuming load device is supplied solely by electrical power supplied by the metal-air fuel cell battery subsystem.

26. The method of claim 25, wherein electrical power provided to the electrical power-consuming load device is supplied solely by electrical power generated by discharging the metal-air fuel cell battery subsystem.

27. The method of claim 24, further comprising an input power bus and output power bus both coupled to the metal-air fuel cell battery subsystem, wherein the input power bus provides an electrical connection from the external power source to the metal-fuel cell battery subsystem in the recharging mode to thereby recharge the metal-air fuel cell battery system, and wherein the output power bus provides an electrical connection from the metal-fuel cell battery subsystem to said electrical power-consuming load device in the discharging mode to thereby provide electrical power to the electrical power-consuming load device.

28. The method of claim 27, wherein the metal-air fuel cell battery subsystem comprises a network of metal-air fuel cell modules each comprising a plurality of metal-air fuel cells, wherein the network of metal-air fuel cell modules includes a first set of modules distinct from a second set of modules;

and wherein said controller operates the first set of modules in discharging mode to thereby supply electrical power from the first set of modules to said electrical power-consuming load device via the output power bus concurrent with operation of the second set of modules in recharging mode to thereby recharge the second set of modules with electrical power supplied from the external power source via the input power bus.

29. The method of claim 27, wherein the metal-air fuel cell battery subsystem comprises a plurality of metal-air fuel cells including a first set of metal-air fuel cells distinct from a second set of fuel cells;

and said controller operates the first set of fuel cells in discharging mode to thereby supply electrical power from the first set of fuel cells to said electrical power-consuming load device via the output power bus concurrent with operation of the second set of fuel cells in recharging mode to thereby recharge the second set of fuel cells with electrical power supplied from the external power source via the input power bus.

30. The method of claim 24, wherein said system housing includes recesses into which metal-fuel is manually loaded into the metal-air fuel cell battery subsystem and from which metal-fuel is manually unloaded from the metal-air fuel cell battery subsystem.

31. The method of claim 30, wherein the metal-fuel is disposed on a card structure that is manually loaded into and unloaded from the recesses.

32. The method of claim 31, wherein the card structure comprises a plurality of distinct metal-fuel elements integrated therein.

33. The method of claim 30, wherein the metal-fuel is disposed in a cartridge that is that is manually loaded into and unloaded from the recesses.

34. The method of claim 33, wherein the cartridge holds metal-fuel tape.

35. The method of claim 33, wherein the cartridge holds sheets of metal-fuel.

36. The method of claim 33, wherein the cartridge stores a paste including anode material particles suspended in a liquid ionically-conducting medium.

46. The method of claim 28, further comprising the step of:

operating a switching network coupled to the input power bus, the output power bus, and the power terminals of a plurality of metal-air fuel cell battery subsystems, in response to control signals from said controller, to;

selectively couple the input power bus to the power terminals of one or more of the plurality of metal-air fuel cell battery subsystems;

to selectively couple the output power bus to the power terminals of one or more of the plurality of metal-air fuel cell battery subsystems; and

to selectively couple together the power terminals of two or more of the metal-air fuel cell battery subsystems.

37. The method of 24, wherein the appliance comprises a computer processing apparatus.

38. The method of 24, wherein the appliance comprises a portable electronic device.

39. The method of claim 38, wherein the portable electronic device is one of the following:

radio, disc player, other portable music playing devices, camcorder, other video playing/recording devices, telephone, PDA, other communication devices.

40. The method of 24, where the appliance comprises one of the following:

television, audio equipment, washing machine, refrigerator, freezer, oven, stove, furnace, air conditioner.

41. The method of 24, wherein the appliance comprises an electrically-powered tool.

42. The method of 24, wherein the external power source comprises a public electric utility grid.

43. The method of 24, wherein the external power source derives energy from a public utility grid.

44. The method of 24, wherein the external power source comprises a wind-driven power generator.

45. The method of 24, wherein the external power source comprises a generator that derives energy from solar energy.