Form Energy, Inc.

Arizona State University

Fluidic, Inc.

Nantenergy, Inc.

Lawrence Livermore National Security, LLC

Joel Ryan Hayes

Ramkumar Krishnan

Cody A Friesen

Todd Trimble

Grant Harrison Friesen

Scott L Klug

Shawn Fink

Clifford Anderson

Sergey Puzhaev

Patrick Samuelson

Robert August Zeller

Gregory Nyce

Patrick Samuleson

Craig Trzebny

Joshua D Kuntz

Andrew Goodfellow

Michael Mihalka

Mark Naden

Jushua David Kuntz

Allison Michelle Engstrom

Erika Lyn Engstrom

Jonathan Goldberg

Kent Berchin-Miller

Scott Klug

Rumkumar Krishnan

John Michael Mihalka

A fuel electrode incorporates a first and second corrugated portion that are attached to each other at offset angles respect to their corrugation axis and therefore reinforce each other. A first corrugated portion may extend orthogonally with respect to a second corrugated portion. The first and second corrugated portions may be formed from metal wire and may therefore have a very high volumetric void fraction and a high surface area to volume ratio (sa/vol). In addition, the strands of the wire may be selected to enable high conductivity to the current collectors while maximizing the sa/vol. In addition, the shape of the corrugation, including the period distance, amplitude and geometry may be selected with respect to the stiffness requirements and electrochemical cell application factors. The first and second corrugated portions may be calendared or crushed to reduce thickness of the fuel electrode.

Corrugated fuel electrode

An electrochemical cell includes a mist elimination system that prevents mist from escaping from the cell chamber and conserves moisture within the cell. An exemplary mist elimination system includes a spill prevention device that reduces or prevents an electrolyte from escaping from the cell chamber in the event of an upset, wherein the electrochemical cell is tipped over. A mist elimination system includes a recombination portion that reacts with hydrogen to produce water, that may be reintroduced into the cell chamber. A mist elimination system includes a neutralizer portion that reacts with an electrolyte to bring the pH closer to neutral, as acid/base reaction. A mist elimination system includes a filter that captures mist that may be reintroduced into the cell chamber. A mist elimination system includes a hydrophobic filter on the outer surface to prevent water and other liquids from entering into the mist elimination system.

Mist elimination system for electrochemical cells

An electrochemical cell utilizes an air flow device that draws air through the cell from a scrubber that may be removed while the system is operating. The negative pressure generated by the air flow device allows ambient air to enter the cell housing when the scrubber is removed, thereby enabling continued operation without the scrubber. A moisture management system passes outflow air from the cell through a humidity exchange module that transfers moisture to the air inflow, thereby increasing the humidity of the air inflow. A recirculation feature comprising a valve allow a controller to recirculate at least a portion of the outflow air back into the inflow air. The system may comprise an inflow bypass conduit and valve that allows the humidified inflow air to pass into the cell inlet without passing through the scrubber. The scrubber may contain reversible or irreversible scrubber media.

Moisture and carbon dioxide management system in electrochemical cells

An exemplary electrochemical cell incorporates at least a first battery electrode, such as a zinc electrode, at least a second battery electrode, such as a reversible metal electrode such as nickel, and at least an oxidant reduction electrode, such as an air cathode. The oxidant reduction electrode(s) is configured in a cell housing such that it is essentially orthogonal to the first and second electrodes. The cell housing contains electrolyte therein and the electrodes are immersed, at least partially, in the electrolyte. The positioning of the oxidant reduction electrode(s) on the side of the cell and relatively perpendicular to the first and second (metal) electrodes, allows for more consistent ionic resistance across all the metal electrodes. Optionally, a fourth or oxygen evolving electrode may be provided in the cell housing, horizontal, orthogonal, and below the first and second electrodes to provide oxygen bubbles for mixing the electrolyte.

Electrochemical cell having orthogonal arrangement of electrodes

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.

Internal convection cell

Provided is a rechargeable electrochemical cell system for generating electrical current using a fuel and an oxidant. The system includes a plurality of electrochemical cells. A controller is configured to apply an electrical current between charging electrode(s) and a fuel electrode with the charging electrode(s) functioning as an anode and the fuel electrode functioning as a cathode, such that reducible metal fuel ions in the ionically conductive medium are reduced and electrodeposited as metal fuel in oxidizable form on the fuel electrode. The controller may selectively apply current to a charging electrode and third electrode between fuel electrodes of separate cells to increase uniformity of the metal fuel being electrodeposited on the fuel electrode. The controller controls a number of switches to apply current to the electrodes and select different modes for the system. Also provided are methods for charging and discharging an electrochemical cell system, and selecting different modes.

Electrochemical cell comprising an electrodeposited fuel

Disclosed is a hybrid electrochemical cell having two (or more) sub-cells each with different cell chemistry. For example, a second electrochemical sub-cell has a metal fuel electrode with the same type of metal fuel in a first electrochemical sub-cell, but has a different battery chemistry than the first sub-cell. A controller is configured to selectively generate an electrical current from at least one sub-cell in a discharge mode and selectively apply an electrical current to at least one sub cell in a charge mode, e.g., by controlling an open or closed state of switches. The operating modes may be controlled based on input parameters.

Hybrid electrochemical cell systems and methods of operation

An electrochemical cell system and a process for operating the same, the system having at least two fuel electrodes for receiving electrodeposited metal fuel; at least one oxidant electrode spaced apart from the fuel electrode; at least one charging electrode; an ionically conductive medium communicating the electrodes of the electrochemical cell system for conducting ions to support electrochemical reactions at the fuel, oxidant, and charging electrodes; and, one or more controllers configured to operate the cell system in discharging and charging modes and monitor a state of charge for each fuel electrode. The controllers may assign each fuel electrode in a discharging unit having a state-of-charge meeting a predetermined depletion criteria from the discharging unit to the charging unit, and each fuel electrode in the charging unit having a state-of-charge meeting a predetermined loading criteria from the charging unit to the discharging unit.

Method of operating electrochemical cells comprising electrodeposited fuel

The present application relates to a layer of an oxidant electrode having hygrophobic and current collecting properties, and electrochemical metal-air cell utilizing the same.

Hygrophobic conductor layer for electrochemical cell

A system and methods for managing water content in one or more electrochemical cell is disclosed. The system includes a gas-phase conduit for receiving humid gas-phase associated with the electrochemical cell, a desiccator unit connected to each electrochemical cell and configured for extracting water from the humid gas-phase, a heater for selectively heating the desiccator unit, and a carbon dioxide (CO2) scrubber connected to the desiccator unit. The system may capture water vapor at the desiccator unit from a humid gas-phase exiting electrochemical cell, or release water vapor in desiccator unit, via actuation of heater, that is transported into the electrochemical cell depending on the mode of operation. The CO2 scrubber may also be used to capture water vapor, based on the mode of operation.

Water management system in electrochemical cells with vapor return comprising air electrodes

Growing community of inventors

Chandler, AZ, United States of America

Joel Ryan Hayes