Metal-air fuel cell battery system employing a plurality of moving cathode structures for improved volumetric power density

• US 6,335,111 B1
• Filed: 07/03/1998
• Issued: 01/01/2002
• Est. Priority Date: 10/06/1997
• Status: Expired due to Fees

• Current Assignee: Reveo, Inc.
• Original Assignee: Reveo, Inc.
• Inventors: Legbandt, Thomas J., Faris, Sadeg M., Yao, Wayne, Tsai, Tsepin, Chen, Muguo
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US09/110,761
• Time in Patent Office: 1,278 Days
• Field of Search: 429/13, 429/27, 429/68, 429/127
• US Class Current: 429/404
• 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

Abstract

In an air-metal fuel cell battery (FCB) system, wherein a plurality of movable cathode structures are mounted within a compact housing through which metal-fuel tape is transported along a predetermined path while an ionically-conductive medium is disposed between the metal-fuel tape and each movable cathode structure at points of contact. In illustrative embodiments, the movable cathode structures are realized as rotatable cathode cylinders, and transportable cathode belts. The ionically-conductive medium is realized as a solid-state ionically-conductive film applied to the cathode structures and/or metal-fuel tape, as well as ionically-conductive belt structures transported at the same velocity as corresponding cathode structures (e.g. cathode cylinders or belts) at the locus of points at which the ionically-conductive medium contacts the moving cathode structure and the moving metal-fuel tape. By virtue of the present invention, the volumetric power density characteristics of FCB systems can be significantly improved, while the likelihood of damage to the cathode structures and metal-fuel tape is substantially reduced.

Claims

1. A metal-air fuel cell battery system for generating electrical power, comprising:

a plurality of movable cathode structures, each said movable cathode structure being mounted within a housing to enable movement of said movable cathode structure about a closed path;

a supply of metal-fuel tape transportable relative to said movable cathode structures, along a predetermined tape path extending within said housing;

an ionically-conductive medium disposed between said plurality of movable cathodes and said metal-fuel tape during system operation, for contacting each said movable cathode structure and said metal-fuel tape being transported over said movable cathode structure, and supporting ionic conduction between said movable cathode structure and said metal-fuel tape during system operation; and

a transport mechanism for transporting said plurality of movable cathode structures, said metal-fuel tape and said ionically-conductive medium relative to said housing,

wherein each said movable cathode structure is cylindrically shaped and has a hollow center permitting air flow therethrough during system operation.

2. The metal-air fuel cell battery system of claim 1, wherein said ionically-conductive medium is a film integrated with each said movable cathode structure.

3. The metal-air fuel cell battery system of claim 2, wherein said transport mechanism comprises:

first means for transporting said supply of metal-fuel tape relative to each said movable cathode structure within said housing; and

second means for moving each said movable cathode structure relative to and at substantially the same velocity as said metal-fuel tape during system operation.

4. The metal-air fuel cell battery system of claim 3, wherein said first means comprises one or more electric motors for rotating each said movable cathode structure, and said second means comprises one or more electric motors for transporting said metal-fuel tape relative to said each movable cathode structure.

5. The metal-air fuel cell battery system of claim 1, wherein said ionically-conductive medium is a film integrated with said metal-fuel tape.

6. The metal-air fuel cell battery system of claim 5, wherein said transport mechanism comprises:

first means for transporting said supply of metal-fuel tape relative to said movable cathode structure; and

second means for moving said movable cathode structure relative to and at substantially the same velocity as said metal-fuel tape during system operation.

7. The metal-air fuel cell battery system of claim 1, wherein said ionically-conductive medium is an ionically-conductive belt structure transported between each said movable cathode structure and at least a portion of said metal-fuel tape.

8. The metal-air fuel cell battery system of claim 7, wherein said transport mechanism comprises:

first means for transporting said supply of metal-fuel tape relative to each said movable cathode structure;

second means for moving each said movable cathode structure relative to and at substantially the same velocity as said metal-fuel tape during system operation; and

third means for transporting said ionically-conductive belt structure between each said movable cathode structure and said metal-fuel tape during system operation, at substantially the same velocity as said metal-fuel tape during system operation.

9. The metal-air fuel cell battery system of claim 7, wherein said transport mechanism comprises a common belt structure for transporting said movable cathode structure, said ionically-conductive belt structure and said metal-fuel tape relative to each other at substantially the same velocity at the locus of points at which said ionically-conductive belt structure contacts each said movable cathode structure and said metal-fuel tape.

10. The metal-air fuel cell battery system of claim 1, wherein said transport mechanism comprises a common belt structure for transporting each said movable cathode structure and said metal-fuel tape relative to each other at substantially the same velocity at the locus of points at which said ionically-conductive medium contacts said movable cathode structure and said metal-fuel tape.

11. The metal-air fuel cell battery system of claim 1, wherein each said movable cathode structure is a cathode belt structure.

12. The metal-air fuel cell battery system of claim 11, wherein said ionically-conductive medium is a film integrated with each said cathode belt structure.

13. The metal-air fuel cell battery system of claim 11, wherein said ionically-conductive medium is a film integrated with said metal-fuel tape.

14. The metal-air fuel cell battery system of claim 11, wherein said ionically-conductive medium is an ionically-conductive belt structure disposed between at least a portion of each said cathode belt structure and said metal-fuel tape.

15. The metal-air fuel cell battery system of claim 11, wherein said transport mechanism comprises a common belt structure for transporting said cathode belt structure and said metal-fuel tape.

16. The metal-air fuel cell battery system of claim 1, wherein said ionically-conductive medium is an ionically-conductive belt structure transported between each said movable cathode structure and at least a portion of said metal-fuel tape.

17. A metal-air fuel cell battery system for generating electrical power, comprising:

a plurality of movable cathode structures, each said movable cathode structure being mounted within a housing to enable movement of said movable cathode structure about a closed path;

a supply of metal-fuel tape transportable relative to said movable cathode structures, along a predetermined tape path extending within said housing;

an ionically-conductive medium disposed between said plurality of movable cathodes and said metal-fuel tape during system operation, for contacting each said movable cathode structure and said metal-fuel tape being transported thereover, and supporting ionic conduction between said movable cathode structure and said metal-fuel tape during system operation; and

a transport mechanism for transporting said plurality of movable cathode structures, said metal-fuel tape and said ionically-conductive medium relative to said housing,

wherein each said movable cathode structure is a cathode belt structure,

wherein said ionically-conductive medium is a film integrated with each said cathode belt structure, and

wherein said transport mechanism comprises

a first means for transporting said supply of metal-fuel tape relative to each said cathode belt structure, and

a second means for moving each said cathode belt structure relative to and at substantially the same velocity as said metal-fuel tape at the locus of points at which said ionically-conductive medium contacts each said cathode belt structure and said metal-fuel tape during system operation.

18. The metal-air fuel cell battery system of claim 17, wherein said first means comprises one or more electric motors for rotating each said cathode belt structure, and said second means comprises one or more electric motors for transporting said metal-fuel tape relative to each said cathode belt structure.

19. The metal-air fuel cell battery system of claim 17, wherein said transport mechanism further comprises:

a third means for transporting said ionically-conductive belt structure between each said cathode belt structure and said metal-fuel tape during system operation, at substantially the same velocity as said metal-fuel tape at the locus of points at which said ionically-conductive structure contacts said cathode belt structure and said metal-fuel tape during system operation.

20. The metal-air fuel cell battery system of claim 19, wherein said first means comprises one or more electric motors for rotating each said movable cathode structure, and said second means comprises one or more electric motors for transporting said metal-fuel tape relative to each said moving cathode structure.

21. A metal-air fuel cell battery system for generating electrical power, comprising:

a plurality of movable cathode structures, each mounted within a housing to enable movement of said movable cathode structures about a closed path;

a supply of metal-fuel tape transportable relative to said movable cathode structures, along a predetermined tape path extending within said housing;

an ionically-conductive medium disposed between said plurality of movable cathodes and said metal-fuel tape during system operation, for contacting each said movable cathode structure and said metal-fuel tape being transported over said movable cathode structure, and supporting ionic conduction between said movable cathode structure and said metal-fuel tape during system operation; and

a transport mechanism for transporting said plurality of movable cathode structures, said metal-fuel tape and said ionically-conductive medium relative to said housing,

wherein said ionically-conductive medium is an ionically-conductive belt structure transported between each said movable cathode structure and at least a portion of said metal-fuel tape,

wherein said transport mechanism comprises;

a first means for transporting said supply of metal-fuel tape relative to each said movable cathode structure;

a second means for moving each said movable cathode structure relative to and at substantially the same velocity as said metal-fuel tape at the locus of points at which said ionically-conductive medium belt structure contacts each said movable cathode structure and said metal-fuel tape during system operation; and

a third means for transporting said ionically-conductive belt structure between each said movable cathode structure and said metal-fuel tape during system operation, at substantially the same velocity as said metal-fuel tape at the locus of points at which said ionically-conductive medium belt structure contacts said movable cathode structure and said metal-fuel tape during system operation.

22. The metal-air fuel cell battery system of claim 21, wherein said first means comprises one or more electric motors for rotating each said movable cathode structure, and said second means comprises one or more electric motors for transporting said metal-fuel tape relative to each said movable cathode structure.

23. The metal-air fuel cell battery system of claim 21, wherein said transport mechanism comprises a common belt structure for transporting each said movable cathode structure, said ionically-conductive belt structure and said metal-fuel tape relative to each other at substantially the same velocity at the locus of points at which said ionically-conductive belt structure contacts said movable cathode structure and said metal-fuel tape.

24. A method of producing electrical power from a metal-air fuel cell battery (FCB) system having a housing, a plurality of movable cathode structures, a supply of metal-fuel tape, and a source of ionically-conductive medium for supporting ion transport between each said movable cathode structure and said metal-fuel tape during system operation, said method comprising the steps of:

(a) arranging said plurality of moving cathode structures and said supply of metal-fuel tape within said housing so that said ionically-conductive medium is disposed in physical contact with each said movable cathode structure and said metal-fuel tape; and

(b) moving each said movable cathode structure, said metal-fuel tape and said ionically-conductive medium relative to said housing during operation of said system,

wherein each said movable cathode structure is cylindrically shaped and has a hollow center permitting air flow through said movable cathode structure.

25. The method of claim 24, where during step (b), said each movable cathode structure is moved at substantially the same velocity at the locus of points at which said ionically-conductive medium contacts said movable cathode structure and said metal-fuel tape.

26. The method of claim 24, wherein each said movable cathode structure is a cathode belt structure.

27. The method of claim 24, wherein said ionically-conductive medium is a film integrated with said metal-fuel tape.

28. The method of claim 24, wherein said ionically-conductive medium is a film integrated with each said movable cathode structure.

29. The method of claim 24, wherein said ionically-conductive medium is an ionically-conductive belt structure disposed between at least a portion of said movable cathode structure and said metal-fuel tape.

30. The method of claim 24, wherein step (b) comprises using one or more electric motors to move each said movable cathode structure and said metal-fuel tape.

31. The method of claim 24, wherein step (b) comprises using a common belt structure to move each said cathode belt structure and said metal-fuel tape.

32. A metal-air fuel cell battery (FCB) system for generating electrical power, comprising:

a plurality of movable cathode structures, each mounted within a housing to enable movement of said movable cathode structure about a closed path;

a supply of metal-fuel tape transportable relative to said movable cathode structures, along a predetermined tape path extending within said housing; and

an ionically-conductive medium disposed between said plurality of movable cathode structure and said metal-fuel tape during system operation, for contacting each said movable cathode structure and said metal-fuel tape being transported over said movable cathode structure, and supporting ionic conduction between said movable cathode structure and said metal-fuel tape during system operation.

33. The metal-air fuel cell battery (FCB) system of claim 32, which further comprises

a transport mechanism for transporting said plurality of movable cathode structures, said metal-fuel tape and said ionically-conductive medium relative to said housing.

34. A metal-air fuel cell battery system for generating electrical power, comprising:

a plurality of movable cathode structures mounted within a housing; and

a supply of metal-fuel tape transportable relative to said plurality of movable cathode structures during operation of said system,

wherein each said movable cathode structure has an ionically-conductive coating on the outer surface of said movable cathode structure, disposed between said movable cathode structure and said metal-fuel tape, for contacting said movable cathode structure and said metal-fuel tape and supporting ionic conduction between said movable cathode structure and said metal-fuel tape during operation of said system.

35. The metal-air fuel cell battery system of claim 34, which further comprises

a transport mechanism for transporting said metal-fuel tape relative to said plurality of movable cathode structures during operation of said system.

36. A metal-air fuel cell battery system for generating electrical power, comprising:

a plurality of cathode structures mounted within a housing;

a supply of metal-fuel tape transportable relative to said plurality of cathode structures during operation of said system; and

an ionically-conductive belt disposed between each said cathode structure and said metal-fuel tape, for contacting each said cathode structure and said metal-fuel tape and supporting ionic conduction between said cathode structure and said metal-fuel tape during operation of said system.

37. The metal-air fuel cell battery system of claim 36, which further comprises

a transport mechanism for transporting said ionically-conductive belt relative to said metal-fuel tape and said plurality of cathode structures during operation of said system.