Collection, storage and use of metal-air battery pack effluent

• US 8,298,692 B2
• Filed: 01/26/2011
• Issued: 10/30/2012
• Est. Priority Date: 08/10/2010
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Hermann, Weston Arthur
• Primary Examiner(s): Lee, Cynthia
• Application Number:
  US13/013,852
• Publication Number:
  US 20120040253A1
• Time in Patent Office: 643 Days
• Field of Search: None
• US Class Current: 429/50
• CPC Class Codes: B60K 15/03519 Valve arrangements in the vent line
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: H01M 10/445 in response to gas pressure
• 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 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 8/04089 of gaseous reactants
• CPC Class Codes: H01M 8/0606 with means for production of gaseous reactants
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A system and method for collecting, storing and using the oxygen-rich effluent generated when charging a metal-air battery pack is provided.

Claims

1. A battery pack optimization system, comprising:

a battery pack comprised of at least one metal-air cell and further comprised of a battery pack air outlet and a battery pack air inlet, wherein said battery pack is configured for use within an electric vehicle and to provide power to said electric vehicle;

a gas tank mounted within said electric vehicle, wherein said battery pack air outlet is coupled to a tank inlet of said gas tank, and wherein said battery pack air inlet is coupled to a tank outlet of said gas tank; and

a compressor interposed between said battery pack air outlet and said tank inlet, said compressor configured to compress oxygen-rich effluent from said battery pack air outlet prior to filling said gas tank with said oxygen-rich effluent.

2. The battery pack optimization system of claim 1, further comprising a system controller, said system controller configured to open at least a first valve controlling oxygen-rich effluent flow from said battery pack air outlet to said compressor and said tank inlet during a battery pack charge cycle, and configured to open at least a second valve controlling oxygen-rich effluent flow from said tank outlet to said battery pack air inlet during a battery pack discharge cycle.

3. The battery pack optimization system of claim 2, said system controller configured to initiate operation of said compressor during said battery pack charge cycle.

4. The battery pack optimization system of claim 2, said system controller configured to close said first valve controlling oxygen-rich effluent flow from said battery pack air outlet to said compressor and said tank inlet during said battery pack discharge cycle, and configured to close said second valve controlling oxygen-rich effluent flow from said tank outlet to said battery pack air inlet during said battery pack charge cycle.

5. The battery pack optimization system of claim 2, said system controller configured to open a third valve controlling air flow from an ambient environment to said battery pack air inlet during said battery pack charge cycle.

6. The battery pack optimization system of claim 5, wherein said third valve is coupled to a one way valve, said one way valve allowing air flow into said battery pack inlet.

7. The battery pack optimization system of claim 2, said system controller configured to open a third valve controlling air flow from said tank outlet to said ambient environment during said battery pack discharge cycle.

8. The battery pack optimization system of claim 7, wherein said third valve is coupled to a one way valve, said one way valve allowing air flow out of said battery pack outlet.

9. The battery pack optimization system of claim 2, further comprising at least one pressure monitor coupled to said system controller, said system controller configured to initiate operation of said compressor during said battery pack charge cycle when said pressure monitor indicates a pressure in excess of a preset pressure.

10. The battery pack optimization system of claim 2, further comprising at least one battery pack pressure monitor coupled to said system controller, said system controller configured to maintain battery pack pressure within a preset pressure range.

11. The battery pack optimization system of claim 2, further comprising at least one battery pack oxygen monitor coupled to said system controller, said system controller configured to modulate flow of oxygen-rich effluent from said tank outlet to said battery pack air inlet during said battery pack discharge cycle to maintain battery pack oxygen levels within a preset oxygen range.

12. The battery pack optimization system of claim 1, further comprising a heat exchanger interposed between said battery pack outlet and said compressor.

13. The battery pack optimization system of claim 1, further comprising a battery pack charger circuit, wherein said compressor receives power from said battery pack charger circuit.

14. A method of operating a metal-air battery pack mounted within an electric vehicle, the method comprising the steps of:

coupling a battery pack outlet to a tank inlet of a gas tank mounted within said electric vehicle, wherein a compressor is interposed between said battery pack outlet and said tank inlet;

coupling a battery pack inlet to a tank outlet of said gas tank;

compressing oxygen-rich effluent passing through said battery pack outlet with said compressor, wherein said oxygen-rich effluent is at least partially generated by said metal-air battery pack, and wherein said compressing step is performed during a battery pack charge cycle;

storing said oxygen-rich effluent compressed by said compressor during said battery pack charge cycle in said gas tank; and

transferring said oxygen-rich effluent through said tank outlet of said gas tank to said battery pack inlet of said metal-air battery pack during a battery pack discharge cycle.

15. The method of claim 14, further comprising the steps of initiating operation of said compressor during said battery pack charge cycle, and terminating operation of said compressor during said battery pack discharge cycle.

16. The method of claim 14, further comprising the steps of closing said tank outlet and said battery pack inlet during said battery pack charge cycle.

17. The method of claim 14, further comprising the steps of closing said tank inlet and said battery pack outlet during said battery pack discharge cycle.

18. The method of claim 14, further comprising the steps of closing said tank outlet during said battery pack discharge cycle, and opening an ambient air battery pack inlet during said battery pack discharge cycle.

19. The method of claim 14, further comprising the steps of closing said tank inlet during said battery pack charge cycle, and opening an ambient air battery pack outlet during said battery pack charge cycle.

20. The method of claim 19, further comprising the step selecting a one way inlet for said ambient air battery pack outlet, wherein said one way inlet allows ambient air to pass into said metal air battery pack during said battery pack charge cycle and does not allow said oxygen-rich effluent to pass out of said one way inlet.

21. The method of claim 14, further comprising the steps of monitoring pressure within said metal-air battery pack, comparing said pressure to a preset pressure level, and initiating operation of said compressor during said battery pack charge cycle when said pressure is above said preset pressure level and terminating operation of said compressor during said battery pack charge cycle when said pressure is below said preset pressure level.

22. The method of claim 14, further comprising the steps of monitoring pressure at a compressor inlet, comparing said pressure to a preset pressure level, and initiating operation of said compressor during said battery pack charge cycle when said pressure is above said preset pressure level and terminating operation of said compressor during said battery pack charge cycle when said pressure is below said preset pressure level.

23. The method of claim 14, further comprising the steps of monitoring oxygen levels within said metal-air battery pack, comparing said oxygen levels to a preset oxygen range, and modulating flow of said oxygen-rich effluent from said tank outlet to said battery pack inlet during said battery pack discharge cycle to maintain said oxygen level to within said preset oxygen range.

24. The method of claim 14, further comprising the steps of passing said oxygen-rich effluent through a heat exchanger, said heat exchanger located between said battery pack outlet and said compressor.

25. The method of claim 24, further comprising the steps of withdrawing heat from said oxygen-rich effluent utilizing said heat exchanger during at least a portion of said battery pack charge cycle.