Internal convection cell

• US 8,906,563 B2
• Filed: 06/25/2012
• Issued: 12/09/2014
• Est. Priority Date: 11/04/2011
• Status: Active Grant

• Current Assignee: Form Energy, Inc.
• Original Assignee: Fluidic, Inc.
• Inventors: Friesen, Cody A, Krishnan, Ramkumar, Friesen, Grant, Hayes, Joel
• Primary Examiner(s): Gilliam, Barbara
• Assistant Examiner(s): Essex, Stephan
• Application Number:
  US13/532,374
• Publication Number:
  US 20130115532A1
• Time in Patent Office: 897 Days
• US Class Current: 429/407
• 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 4/8605 Porous electrodes
• CPC Class Codes: H01M 50/73 Electrolyte stirring by the action of gas on or in the electrolyte
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An electrochemical cell includes a permeable fuel electrode configured to support a metal fuel thereon, and an oxidant reduction electrode spaced from the fuel electrode. An ionically conductive medium is provided for conducting ions between the fuel and oxidant reduction electrodes, to support electrochemical reactions at the fuel and oxidant reduction electrodes. A charging electrode is also included, selected from the group consisting of (a) the oxidant reduction electrode, (b) a separate charging electrode spaced from the fuel and oxidant reduction electrodes, and (c) a portion of the permeable fuel electrode. The charging electrode is configured to evolve gaseous oxygen bubbles that generate a flow of the ionically conductive medium. One or more flow diverters are also provided in the electrochemical cell, and configured to direct the flow of the ionically conductive medium at least partially through the permeable fuel electrode.

Claims

1. An electrochemical cell comprising:

a permeable fuel electrode configured to support a metal fuel thereon;

an oxidant reduction electrode spaced from the fuel electrode;

a second oxidant reduction electrode spaced from and opposing the oxidant reduction electrode, with the permeable fuel electrode being positioned between the oxidant reduction electrode and the second oxidant reduction electrode;

an ionically conductive medium for conducting ions between the fuel and oxidant reduction electrodes to support electrochemical reactions at the fuel and oxidant reduction electrodes;

a charging electrode selected from the group consisting of (a) the oxidant reduction electrode, (b) a separate charging electrode spaced from the permeable fuel electrode and the oxidant reduction electrode, and (c) a portion of the permeable fuel electrode;

a gas bubble flow generator selected from the group consisting of (a) the charging electrode, and (b) a sparger spaced from the charging electrode, the gas bubble flow generator being configured to evolve gaseous oxygen bubbles that generate a flow of the ionically conductive medium during a charging operation; and

one or more flow diverting surfaces configured to establish a circulation path that directs the flow of the ionically conductive medium at least partially through the permeable fuel electrode;

wherein the oxidant reduction electrode is immersed in the ionically conductive medium with an air space associated therewith to provide a gaseous oxidant thereto, wherein the one or more flow diverting surfaces includes a flow diverting surface configured to direct the flow of the ionically conductive medium upwardly and then laterally over a top of the oxidant reduction electrode and the air space, to a side thereof opposite the fuel electrode.

2. The electrochemical cell of claim 1, further comprising an off-gassing area configured to permit the gaseous oxygen bubbles to separate from the ionically conductive medium in the flow of ionically conductive medium.

3. The electrochemical cell of claim 2, wherein the off-gassing area comprises a column.

4. The electrochemical cell of claim 2, wherein the oxidant reduction electrode is assembled into an oxidant reduction electrode module configured to maintain the air space therein, and wherein the oxidant reduction electrode module bounds at least a portion of the off-gassing area on the side thereof opposite the fuel electrode.

5. The electrochemical cell of claim 2, wherein the one or more flow diverting surfaces comprises a flow diverting surface configured to direct the flow of ionically conductive medium from the off-gassing area to a region of the fuel electrode distal from the oxidant reduction electrode and the charging electrode.

6. The electrochemical cell of claim 5, wherein the one or more flow diverting surfaces comprises a diffuser for directing the flow of ionically conductive medium generally perpendicularly into a face of the fuel electrode.

7. The electrochemical cell system of claim 2, wherein the off-gassing area comprises one or more bubble coalescing structures.

8. The electrochemical cell system of claim 7, wherein the one or more bubble coalescing structures comprise hydrophobic matting.

9. The electrochemical cell system of claim 1, wherein the fuel electrode comprises a series of permeable electrode bodies arranged in spaced apart relation.

10. The electrochemical cell of claim 9, wherein the one or more flow diverting surfaces comprises a flow diverting surface configured to prevent at least a portion of the flow from passing through less than all of the series of permeable electrode bodies of the fuel electrode.

11. The electrochemical cell of claim 10, wherein the one or more flow diverting surfaces comprises a flow diverting surface configured to prevent at least a portion of the flow from passing through less than all of the series of permeable electrode bodies comprises a wall extending across a top of the fuel electrode.

12. The electrochemical cell of claim 9, wherein the one or more flow diverting surfaces comprises a flow diverting surface configured to direct the flow of the ionically conductive medium at least partially through the permeable fuel electrode are configured to direct the flow generally parallel and between the series of permeable electrode bodies.

13. The electrochemical cell of claim 1, wherein the one or more flow diverting surfaces comprises a flow diverting surface configured to prevent the flow from rising above a top of the fuel electrode on a side of the fuel electrode distal from the charging electrode.

14. The electrochemical cell of claim 1, wherein the gas bubble flow generator comprises both the charging electrode and the sparger.

15. The electrochemical cell of claim 1, wherein the sparger comprises an air pump configured to emit bubbles of gas into the ionically conductive medium.

16. The electrochemical cell of claim 15, wherein the sparger further comprises one or more microtubes configured to generate the bubbles of the gas in the electrochemical cell.

17. The electrochemical cell of claim 1, wherein at least some of the bubbles emitted by the sparger are approximately less than 1 mm in diameter.

18. The electrochemical cell of claim 17, wherein a majority of the bubbles generated by the sparger are approximately less than 100 μ

m in diameter.

19. The electrochemical cell of claim 18, wherein the majority of bubbles generated by the sparger are approximately between 1 μ

m and 100 μ

m in diameter.

20. The electrochemical cell of claim 1, wherein the fuel electrode and the oxidant reduction electrode are configured to, during discharge, oxidize the metal fuel at the fuel electrode and reduce an oxidant at the oxidant reduction electrode to generate a discharge potential difference therebetween for application to a load.

21. The electrochemical cell of claim 1, wherein the fuel electrode and the charging electrode are configured to, during re-charge, reduce a reducible species of the metal fuel to electrodeposit the metal fuel on the fuel electrode and oxidize an oxidizable species of the oxidant by application of a re-charge potential difference therebetween from a power source.

22. The electrochemical cell of claim 1, wherein the ionically conductive medium comprises an aqueous electrolyte solution.

23. The electrochemical cell of claim 22, wherein the aqueous electrolyte solution comprises sulfuric acid, phosphoric acid, triflic acid, nitric acid, potassium hydroxide, sodium hydroxide, sodium chloride, potassium nitrate, lithium chloride, an organic solvent, or an ionic liquid.

24. The electrochemical cell of claim 1, further comprising a bubble size limiter in the ionically conductive medium, configured to minimize a size of the bubbles generated by the bubble generator.

25. The electrochemical cell of claim 24, wherein the bubble size limiter comprises a surfactant.

26. The electrochemical cell of claim 1, wherein the permeable fuel electrode is a common fuel electrode associated with both the oxidant reduction electrode and the second oxidant reduction electrode, such that during discharge, the metal fuel on the common fuel electrode is oxidized while an oxidant at each of the oxidant reduction electrode and the second oxidant reduction electrode is reduced.

27. The electrochemical cell of claim 1, wherein the permeable fuel electrode comprises a first permeable fuel electrode associated with the first oxidant reduction electrode, and a second permeable fuel electrode associated with the second oxidant reduction electrode.

28. The electrochemical cell of claim 1, wherein the one or more flow diverting surfaces are configured to establish a pair of circulation paths that direct flows of the ionically conductive medium around each of the oxidant reduction electrode and the second oxidant reduction electrode, before flowing at least partially through the permeable fuel electrode.

29. The electrochemical cell of claim 28, wherein the one or more flow diverting surfaces establishes the pair of circulation paths as closed circuits within the cell.

30. The electrochemical cell of claim 28, wherein the gas bubble flow generator is only the charging electrode.

31. The electrochemical cell of claim 1, wherein the gas bubble flow generator is only the charging electrode.

32. The electrochemical cell of claim 1, wherein the second oxidant reduction electrode is immersed in the ionically conductive medium with a second air space associated therewith to provide a gaseous oxidant thereto, wherein the one or more flow diverting surfaces includes a flow diverting surface configured to direct the flow of the ionically conductive medium upwardly and then laterally over a top of the second oxidant reduction electrode and the air second space, to a side thereof opposite the fuel electrode.

33. The electrochemical cell of claim 32, wherein the oxidant reduction electrode is assembled into an oxidant reduction electrode module configured to maintain the air space therein, and wherein the second oxidant reduction electrode is assembled into a second oxidant reduction electrode module configured to maintain the second air space therein, with the permeable fuel electrode being positioned between the oxidant reduction electrode and the second oxidant reduction electrode, with the permeable fuel electrode being positioned between the oxidant reduction electrode and the second oxidant reduction electrode.

34. The electrochemical cell of claim 33, wherein the permeable fuel electrode is a common fuel electrode associated with both the oxidant reduction electrode and the second oxidant reduction electrode, such that during discharge, the metal fuel on the common fuel electrode is oxidized while an oxidant at each of the oxidant reduction electrode and the second oxidant reduction electrode is reduced.

35. An electrochemical cell comprising:

a permeable fuel electrode configured to support a metal fuel thereon;

an oxidant reduction electrode spaced from the fuel electrode;

a second oxidant reduction electrode spaced from and opposing the oxidant reduction electrode, with the permeable fuel electrode being positioned between the oxidant reduction electrode and the second oxidant reduction electrode;

an ionically conductive medium for conducting ions between the fuel and oxidant reduction electrodes to support electrochemical reactions at the fuel and oxidant reduction electrodes;

a charging electrode selected from the group consisting of (a) the oxidant reduction electrode, (b) a separate charging electrode spaced from the permeable fuel electrode and the oxidant reduction electrode, and (c) a portion of the permeable fuel electrode;

a gas bubble flow generator selected from the group consisting of (a) the charging electrode, and (b) a sparger spaced from the charging electrode, the gas bubble flow generator being configured to evolve gaseous oxygen bubbles that generate a flow of the ionically conductive medium during a charging operation; and

one or more flow diverting surfaces configured to establish a circulation path that directs the flow of the ionically conductive medium at least partially through the permeable fuel electrode;

wherein the one or more flow diverting surfaces establishes the circulation path as a closed circuit.

36. The electrochemical cell of claim 35, wherein the circulation path is established within the cell.

37. A method for flowing an ionically conductive medium in an electrochemical cell, the electrochemical cell comprising a permeable fuel electrode configured to support a metal fuel thereon, an oxidant reduction electrode spaced from the fuel electrode, a second oxidant reduction electrode spaced from and opposing the oxidant reduction electrode, with the permeable fuel electrode being positioned between the oxidant reduction electrode and the second oxidant reduction electrode, and a charging electrode selected from the group consisting of (a) the oxidant reduction electrode, (b) a separate charging electrode spaced from the fuel and oxidant reduction electrodes, and (c) a portion of the permeable fuel electrode, the fuel electrode, oxidant reduction electrode, and charging electrode each contacting the ionically conductive medium such that the ionically conductive medium may conduct ions therebetween, the oxidant reduction electrode being immersed in the ionically conductive medium with an air space associated therewith to provide a gaseous oxidant thereto, the method comprising:

emitting gaseous bubbles in the ionically conductive medium that drag the ionically conductive medium upwards due to their buoyancy to generate a flow;

wherein one or more flow diverting surfaces in the electrochemical cell establishes a circulation path that directs the flow of the ionically conductive medium upwardly and then laterally over a top of the oxidant reduction electrode and the air space, to a side thereof opposite the fuel electrode, and at least partially through the permeable fuel electrode.

38. The method of claim 37, wherein said emitting gaseous bubbles comprises charging the electrochemical cell such that the charging electrode evolves gaseous oxygen bubbles.

39. The method of claim 37, wherein said emitting gaseous bubbles comprises utilizing a sparger to introduce bubbles of gas into the electrochemical cell.

40. The method of claim 37, wherein the one or more flow diverting surfaces establishes the circulation path as a closed circuit.

41. The method of claim 37,

wherein the one or more flow diverting surfaces establish a pair of circulation paths to direct the flow around each of the oxidant reduction electrode and the second oxidant reduction electrode, before flowing at least partially through the permeable fuel electrode.

42. The method of claim 41, wherein the one or more flow diverting surfaces establish the pair of circulation paths as closed circuits within the cell.

43. The method of claim 40, wherein the circulation path is established within the cell.

44. A method for flowing an ionically conductive medium in an electrochemical cell, the electrochemical cell comprising a permeable fuel electrode configured to support a metal fuel thereon, an oxidant reduction electrode spaced from the fuel electrode, a second oxidant reduction electrode spaced from and opposing the oxidant reduction electrode, with the permeable fuel electrode being positioned between the oxidant reduction electrode and the second oxidant reduction electrode, and a charging electrode selected from the group consisting of (a) the oxidant reduction electrode, (b) a separate charging electrode spaced from the fuel and oxidant reduction electrodes, and (c) a portion of the permeable fuel electrode, the fuel electrode, oxidant reduction electrode, and charging electrode each contacting the ionically conductive medium such that the ionically conductive medium may conduct ions therebetween, the method comprising:

emitting gaseous bubbles in the ionically conductive medium that drag the ionically conductive medium upwards due to their buoyancy to generate a flow;

wherein one or more flow diverting surfaces in the electrochemical cell establishes a closed circuit circulation path that directs the flow of the ionically conductive medium at least partially through the permeable fuel electrode.