Electrochemical cell with stepped scaffold fuel anode

• US 8,659,268 B2
• Filed: 06/24/2011
• Issued: 02/25/2014
• Est. Priority Date: 06/24/2010
• Status: Active Grant

• Current Assignee: Form Energy, Inc.
• Original Assignee: Fluidic, Inc.
• Inventors: Krishnan, Ramkumar, Friesen, Cody A., Friesen, Grant
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): PIGGUSH, AARON C
• Application Number:
  US13/167,930
• Publication Number:
  US 20110316485A1
• Time in Patent Office: 977 Days
• Field of Search: 320/128, 320/137, 429/122, 429/188, 429/488
• US Class Current: 320/137
• CPC Class Codes: H01M 12/065 with plate-like electrodes or stacks of plate-like electrodes
• 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 12/085 Zinc-halogen cells or batteries
• CPC Class Codes: H01M 4/244 Zinc electrodes
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An electrochemical cell includes a fuel electrode configured to operate as an anode to oxidize a fuel when connected to a load, and configured to operate as a cathode when connected to a power supply. The fuel electrode comprises a plurality of scaffolded electrode bodies, wherein the scaffolded electrode bodies are of varying size. The electrode bodies are of a larger size at positions distal from a charging electrode configured to act as an anode when connected to the power supply, and of a smaller size at positions proximal to the charging electrode. When connected to a load, the scaffolded electrode bodies-containing fuel electrode acts as the electrochemical cell anode and electrodeposited fuel is oxidized.

Claims

1. A method for operating an electrochemical cell, wherein the cell comprises:

a fuel electrode comprising a series of permeable electrode bodies arranged in spaced apart relation;

an oxidant electrode spaced apart from the fuel electrode;

a charging electrode spaced apart from the fuel electrode, the charging electrode being selected from the group consisting of (a) the oxidant electrode, and (b) a separate charging electrode spaced apart from the oxidant electrode;

an ionically conductive medium communicating the electrodes;

the series of permeable electrode bodies of the fuel electrode comprising;

a proximal permeable electrode body, proximal to the charging electrode;

a distal permeable electrode body, distal from the charging electrode;

wherein, in a direction from the distal permeable electrode body to the proximal permeable electrode body, at least a portion of a peripheral edge of the proximal permeable electrode body is located inward of at least a portion of a peripheral edge of the distal permeable electrode body;

wherein the method comprises;

charging the electrochemical cell by;

i. applying an electrical current between the charging electrode and at least one of the permeable electrode bodies of the fuel electrode with the charging electrode functioning as an anode and the at least one permeable electrode body functioning as a cathode, such that reducible fuel ions are reduced and electrodeposited as fuel in oxidizable form on the at least one permeable electrode body;

ii, said electrodeposition causing growth of the fuel among the permeable electrode bodies such that the electrodeposited fuel establishes an electrical connection between the permeable electrode bodies; and

iii. removing the electrical current to discontinue the charging.

2. A method according to claim 1, wherein the proximal electrode body has a lesser planar size than the distal permeable electrode body.

3. The method of claim 1, wherein the method further comprises:

generating electrical current using the electrochemical cell by oxidizing the fuel on the permeable electrode bodies of the fuel electrode functioning as an anode and reducing an oxidizer at the oxidant electrode functioning as a cathode wherein electrons are generated for conduction from the fuel electrode to the oxidant electrode via a load, and the oxidized fuel ions and reduced oxidizer ions react to form a by-product.

4. A method according to claim 3, wherein the oxidizer comprises oxygen, and wherein the oxidant electrode comprises an electrode configured to absorb and reduce atmospheric oxygen.

5. A method according to claim 1, wherein the reducible fuel ions are reducible metal fuel ions and the electrodeposited fuel is electrodeposited metal fuel,

6. A method according to claim 5, wherein the reducible metal fuel'"'"' ions comprise ions of zinc, iron, aluminum, magnesium, or lithium, and wherein the electrodeposited metal fuel is zinc, iron, aluminum, magnesium, or lithium.

7. A method according to claim 5, wherein during said charging the electrochemical cell:

the electrical current is applied to a terminal one of the permeable electrode bodies, such that the reducible metal fuel ions are reduced and electrodeposited as metal fuel in oxidizable form on the terminal permeable electrode body;

said electrodeposition causing growth of the metal fuel among the permeable electrode bodies such that the electrodeposited metal fuel establishes an electrical connection between the terminal electrode body and the proximal permeable electrode body with said reduction and deposition occurring on the proximal permeable electrode body upon establishment of said electrical connection.

8. A method according to claim 7, wherein the fuel electrode further comprises one or more intermediate permeable electrode bodies;

wherein said electrical connection between the terminal electrode body and the proximal permeable electrode body is established through each of said one or more intermediate permeable electrode bodies with said reduction and deposition occurring on each of the one or more intermediate permeable electrode bodies upon establishment of said electrical connection.

9. A method according to claim 7, wherein the ionically conductive medium is an electrolyte.

10. A method according to claim 9, wherein during said charging the electrochemical cell the electrolyte flows along a flow path through the permeable electrode bodies, and said electrodeposition causes growth of the metal fuel in a flow permeable morphology.

11. A method according to claim 10, wherein said growth of the metal fuel is selected from the group consisting of dense branch morphology growth and dendritic growth.

12. A method according to claim 10, wherein the growth of the metal fuel is in a direction towards the charging electrode.

13. A method according to claim 12, wherein the terminal permeable electrode body is the distal permeable electrode body.

14. A method according to claim 12, wherein said growth of the metal fuel is selected from the group consisting of dense branch morphology growth and dendritic growth.

15. A method according to claim 13, wherein said growth of the metal fuel is selected from the group consisting of dense branch morphology growth and dendritic growth.

16. A method according to claim 1, wherein the charging electrode is the oxidant electrode.

17. A method according to claim 1, wherein the charging electrode is the separate charging electrode spaced from the oxidant electrode.

18. A method according to claim 1, wherein at least a portion of the peripheral edge of the fuel electrode is coated in an insulating material.

19. A method according to claim 18, wherein the insulating material comprises plastic and/or epoxy.

20. An electrochemical cell comprising:

a fuel electrode comprising a series of permeable electrode bodies arranged in spaced apart relation;

an oxidant electrode spaced apart from the fuel electrode;

a charging electrode spaced apart from the fuel electrode, the charging electrode being selected from the group consisting of (a) the oxidant electrode, and (b) a separate charging electrode also spaced apart from the oxidant electrode;

an ionically conductive medium communicating the electrodes;

the series of permeable electrode bodies of the fuel electrode comprising;

a proximal permeable electrode body, proximal to the charging electrode;

a distal permeable electrode body, distal from the charging electrode;

wherein, in a direction from the distal permeable electrode body to the proximal permeable electrode body, at least a portion of a peripheral edge of the proximal permeable electrode body is located inward of at least a portion of a peripheral edge of the distal permeable electrode body,

wherein the spaced apart relation of said permeable electrode bodies of the fuel electrode enables an electrical current to be applied between the charging electrode and at least one of the permeable electrode bodies of the fuel electrode with the charging electrode functioning as an anode and the at least one permeable electrode body functioning as a cathode, such that reducible fuel ions are reduced and electrodeposited as fuel in oxidizable form on the at least one permeable electrode body, wherein the electrodeposition causes growth of the fuel among the permeable electrode bodies such that the electrodeposited fuel establishes an electrical connection between the permeable electrode bodies.

21. The electrochemical cell of claim 20, wherein the proximal permeable electrode body has a lesser planar size than the distal permeable electrode body.

22. The electrochemical cell of claim 21, wherein the fuel electrode further comprises one or more intermediate permeable electrode bodies, the one or more intermediate permeable electrode bodies being in spaced relation between the distal permeable electrode body and the proximal permeable electrode body,

wherein each of the permeable electrode bodies more proximal to the charging electrode has a lesser planar size than each of the permeable electrode bodies more proximal to the charging electrode, such that along at least a portion of a peripheral edge of the fuel electrode, the edges of each of the proximal and intermediate permeable electrode bodies are located inward of the edge of the adjacent electrode body in the distal direction in a progressive manner.

23. The electrochemical cell of claim 20, wherein the oxidant electrode is configured to, in a discharge mode, absorb and reduce atmospheric oxygen.

24. The electrochemical cell of claim 20, wherein the charging electrode is larger in area than any of the permeable electrode bodies in the series of permeable electrode bodies.

25. The electrochemical cell of claim 20, wherein the charging electrode is smaller in area than any of the permeable electrode bodies in the series of permeable electrode bodies.

26. The electrochemical cell of claim 20, wherein the oxidant electrode is larger in area than any of the permeable electrode bodies in the series of permeable electrode bodies.

27. The electrochemical cell of claim 20, wherein the fuel electrode further comprises one or more intermediate permeable electrode bodies between the distal and proximal electrode bodies, the electrode bodies being spaced apart from one another, wherein along said at least the portion of the fuel electrode, the edges of each of the proximal and intermediate electrode bodies are located inward of the edge of the adjacent electrode body in the distal direction in a progressive manner.

28. The electrochemical cell of claim 20, wherein the reducible fuel ions are reducible metal fuel ions, and the electrodeposited fuel is electrodeposited metal fuel.

29. The electrochemical cell of claim 28, wherein the reducible metal fuel ions comprise ions of zinc, iron, aluminum, magnesium, or lithium, and wherein the electrodeposited metal fuel is zinc, iron, aluminum, magnesium, or lithium.

30. The electrochemical cell of claim 20, wherein the ionically conductive medium comprises an electrolyte.

31. The electrochemical cell of claim 20, wherein the charging electrode is the oxidant electrode.

32. The electrochemical cell of claim 20, wherein the charging electrode is the separate charging electrode spaced from the oxidant electrode.

33. The electrochemical cell of claim 20, further comprising an insulating material configured to insulate at least a portion of the peripheral edge of the fuel electrode.

34. The electrochemical cell of claim 33, wherein the insulating material comprises plastic and/or epoxy.

35. A method for operating an electrochemical cell, wherein the cell comprises:

a fuel electrode comprising a series of permeable electrode bodies arranged in spaced apart relation;

an oxidant electrode spaced apart from the fuel electrode;

a charging electrode;

an ionically conductive medium communicating the electrodes;

wherein at least a portion of peripheral edges of the permeable electrode bodies are arranged in an inwardly stepped configuration in a direction of fuel growth;

wherein the method comprises;

charging the electrochemical cell by;

i. applying an electrical current between the charging electrode and at least one of the permeable electrode bodies of the fuel electrode with the charging electrode functioning as an anode and the at least one permeable electrode body functioning as a cathode, such that reducible fuel ions are reduced and electrodeposited as fuel in oxidizable form on the at least one permeable electrode body;

ii. said electrodeposition causing growth of the fuel among the permeable electrode bodies in the first direction such that the electrodeposited fuel establishes an electrical connection between the permeable electrode bodies; and

iii, removing the electrical current to discontinue the charging.

36. The method of claim 35, wherein the charging electrode is selected from the group consisting of (a) the oxidant electrode, (b) a third electrode spaced from the oxidant electrode, and (c) one or more bodies of the fuel electrode.

37. An electrochemical cell comprising:

a fuel electrode comprising a series of permeable electrode bodies arranged in spaced apart relation;

an oxidant electrode spaced apart from the fuel electrode;

a charging electrode;

an ionically conductive medium communicating the electrodes;

wherein at least a portion of peripheral edges of the permeable electrode bodies are arranged in an inwardly stepped configuration in a direction of fuel growth;

wherein the spaced apart relation of said permeable electrode bodies of the fuel electrode enables an electrical current to be applied between the charging electrode and at least one of the permeable electrode bodies of the fuel electrode with the charging electrode functioning as an anode and the at least one permeable electrode body functioning as a cathode, such that reducible fuel ions are reduced and electrodeposited as fuel in oxidizable form on the at least one permeable electrode body, wherein the electrodeposition causes growth of the fuel among the permeable electrode bodies in the direction of fuel growth such that the electrodeposited fuel establishes an electrical connection between the permeable electrode bodies.

38. The electrochemical cell of claim 37, wherein the charging electrode is selected from the group consisting of (a) the oxidant electrode, (b) a third electrode spaced from the oxidant electrode, and (c) one or more bodies of the fuel electrode.