Electro-chemical power generation systems employing arrays of electronically-controllable discharging and/or recharging cells within a unitary support structure

• US 6,562,494 B1
• Filed: 08/03/2000
• Issued: 05/13/2003
• 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:
  US09/632,329
• Time in Patent Office: 1,013 Days
• Field of Search: 429/4, 429/9, 429/27, 429/28, 429/40
• US Class Current: 429/9
• 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 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• 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 16/00 Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 50/50 Current conducting connections for cells or batteries
• CPC Class Codes: H01M 6/12 with flat electrodes
• CPC Class Codes: H01M 6/42 Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: H01M 6/5011 for several cells simultaneously or successively
• CPC Class Codes: H01M 6/5016 Multimode utilisation
• 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

Abstract

A novel fuel cell battery construction having arrays of different type metal-air fuel cells. The first type-cells are preferably formed by a cathode structure having a plurality of first-type cathode elements, and an anode structure having one or more anode-contacting elements on an anode-contacting element support plate. The second-type-cells are preferably formed by a cathode structure having a plurality of second-type cathode elements, and an anode structure having one or more anode-contacting elements on an anode-contacting element support plate. In one embodiment, the first-type cathode elements and corresponding cells are optimized for discharging operations, while the second type of cathode elements and corresponding cells are optimized for recharging operations. Alternatively, the first-type cathode elements and corresponding cells may be optimized for low-power discharging operations, while the second type of cathode elements and corresponding cells are optimized for high-power discharging operations. In addition, each cell is preferably independently activated (i.e. enabled) using a transistor-based power switching element operated under the control of a switching controller. The power switching device elements may be controlled to produce selectable output characteristics (voltage level, current level, etc.) during discharge operations, and control recharging cells during recharging operations. In addition, the power switching elements may be used to produce high-frequency electrical currents for generating stepped-up voltages, which are subsequently rectified and low-pass filtered.

Claims

1. A metal-air FCB system comprising:

a first array of anode-contacting elements arrangeable in spatial registration a first array of cathode elements so as to produce a plurality of first discharging cells for loading metal-fuel material therewithin and generating a first quantity of electrical power therefrom during discharging operations; and

a second array of anode-contacting elements arrangeable in spatial registration to a second array of cathode elements so as to produce a plurality of second discharging cells for loading metal-fuel material therewithin and generating a second quantity of electrical power therefrom during discharging operations,

wherein the second quantity of electrical power generated from the second discharging cells is higher than the first quantity of electrical power generated from the first discharging cells.

2. The metal-air FCB system of claim 1, wherein said low-power and high-power discharging cells are realized within a unitary support structure or subassembly, and each said discharging cell is electronically-controllable in order to carry out any one of a number of output power, voltage and/or current control methods under microprocessor control during discharging operations.

5. The metal-air FCB system of claim 2, wherein each said first cell and each said second discharging cell is switched into operation by a programmed microprocessor.

6. The metal-air FCB system of claim 2, wherein said system can be manually or electro-mechanically translated into its discharging configuration as well as its recharging position, for operation during discharging and recharging operations, respectively.

8. The metal-air FCB system of claim 2, in combination with electrical power consuming devices selected from the group consisting of cellular phones, laptop computer systems, power tools, and automobiles.

10. The metal-air FCB system of claim 2, wherein the high-power discharging cells comprise bifunctional NiOOH cathode structures, which further comprises a metal-fuel management subsystem for automatically managing the amount of metal-fuel remaining on each indexed region of the metal-fuel being discharged so that, during recharging operations, only bifunctional NiOOH cathode structures associated with discharged metal-fuel regions are electrically-switched into operation to enable recharging of such metal-fuel regions.

11. The metal-air FCB system of claim 10, wherein said metal-fuel management subsystem automatically manages the amount of metal-oxide remaining on each region of the metal-fuel being recharged so that, during discharging operations, only cathode structures associated with recharged metal-fuel regions are electrically-switched into operation to enable discharging of such metal-fuel regions.

13. The metal-air FCB system of claim 2, wherein said cathode elements have a microstructure that is optimized for discharging operations.

14. The metal-air FCB system of claim 2, wherein each said cathode element can produce non-DC output using low power rating semiconductor elements, so as to increase the output voltage level using switching power circuits.

3. A metal-air FCB system comprising:

a first array of anode-contacting elements arrangeable in spatial registration a first array of cathode elements so as to produce a plurality of first recharging cells for loading discharged metal-fuel material therewithin and supplying a first quantity of electrical power thereto during recharging operations, and

a second array of anode-contacting elements are provided in spatial registration t a second array of cathode elements so as to produce a plurality of second recharging cells for loading discharging metal-fuel material therewithin and supplying a second quantity of electrical power thereto during recharging operations,

wherein the second quantity of electrical power supplied from the second discharging cells is higher than the first quantity of electrical power supplied from the first discharging cells.

4. The metal-air FCB system of claim 3, wherein said first and second recharging cells are realized within a unitary support structure or subassembly, and each said recharging cell is electronically-controllable in order to carry out any one of the number of input power, voltage and/or current control methods under microprocessor control during recharging operations.

7. The metal-air FCB system of claim 4, wherein said system is electro-mechanically forced to undergo micro-displacements, relative to said recharging-optimized cathode elements, along the longitudinal direction of said recharging cells during recharging operations, in order to inhibit growth of dendrite formations along the metal fuel elements or regions being recharged.

9. The metal-air FCB system of claim 4, wherein said cathode elements are positioned and vibrated relative to anode elements of the system during recharging operations in order to cause the anode elements to have a different direction of redeposition, thereby reducing dendrite growth and anode shape change during recharging operations.

12. The metal-air FCB system of claim 4, wherein said cathode elements are realized using gas permeable structures having a microstructure provided with micro-pores.

15. A metal air fuel cell battery device for discharging or storing power using electrochemical reactions comprising:

a first array of cathode elements arrangeable in spatial registration to a first array of anode elements so as to produce a plurality of first cells when a metal fuel card is inserted in ionic contact with the first array of cathode elements and in electrical contact with the first array of anode elements;

a second array of cathode elements arrangeable in spatial registration to a second array of anode elements so as to produce a plurality of second cells when said metal fuel card is inserted in ionic contact with the second array of cathode elements and in electrical contact with second first array of anode elements.

16. The device of claim 15, wherein the first cells are used for lower power discharging operations as compared to the second cells.

17. The device of claim 15, wherein the first cells are discharge-optimized for use during discharging operations and the second cells are recharge-optimized for use during recharging operations.

18. The device of claim 17, which further comprises a metal-fuel management subsystem for automatically managing metal-fuel remaining on each indexed region of metal-fuel being discharged so that, during recharging operations, only the second cells associated with discharged metal-fuel regions are electrically-switched into operation to enable recharging of such metal-fuel regions.

19. The device of claim 18, wherein said metal-fuel management subsystem automatically manages the amount of metal-oxide remaining on each region of the metal-fuel being recharge so that, during discharging operations, only first cells associated with recharged metal-fuel regions are electrically-switched into operation to enable discharging of such metal-fuel regions.

20. The device of claim 15, wherein a plurality of either the first cells or said second cells can produce non-DC output using semiconductor elements, so as to increase the output voltage level using switching power circuits.

21. The device of claim 15, in combination with electrical power consuming devices selected from the group consisting of cellular phones, laptop computer systems, power tools and automobiles.