Rayovac Corporation

Other

Eveready Battery Company, Inc.

Quantumsphere, Inc.

Omega Energy Systems, LLC

The Upjohn Co.

Electric Fuel (e.f.l.) Ltd.

Robert B Dopp

John Edward Oltman

Joseph Lynn Passaniti

Gregory Scott Moy

Michael Andrew Ward

John David Burns

Michael J Root

Patrick J Spellman

Randall L Collien

Michael Lee Horovitz

Rodney Stuart McKenzie

Robert Adey

Greyson Williams

Denis D Carpenter

John C Bailey

Richard L Middaugh

Kevin D Maloney

Mariano Abramson

Yaron Shrim

Robert B Loch

Gary A Laisy

Allan Nettleton

Duane M Larsen

Susan Jean Launder

Solid-state energy harvesters comprising layers of metal suboxides and cerium dioxide utilizing a solid-state electrolyte to produce power and methods of making and using the same are provided. The solid-state energy harvester may have two or three electrodes per cell and produces power in the presence of water vapor and oxygen.

Three-electrode solid-state energy harvester of transition metal suboxides

Solid-state energy harvester of transition metal suboxides

Various methods and systems are provided for electrochemical digestion of organic molecules. In one example, among others, a method includes providing an electrolyte fluid including organic molecules between the electrodes of a reaction vessel and applying a voltage wave shape to the electrodes of the reaction vessel to digest the organic molecules. No separator exists between the electrodes of the reaction vessel. In another example, a system for digesting organic molecules includes a reaction vessel, an electrolyte fluid including the organic molecules, and a power source. The reaction vessel includes a plurality of electrodes where no separator exists between the electrodes. The electrolyte fluid is provided between the plurality of electrodes of the reaction vessel and the power source can applies a voltage wave shape to the electrodes of the reaction vessel to digest the organic molecules.

Electrochemical digestion of organic molecules

A process for making a catalytic electrode, a process for making an electrochemical cell with a catalytic electrode, and an electrochemical cell made according to the process. The catalytic electrode has an active layer comprising a catalytic material, an electrically conductive material and a binder, and a gas diffusion layer including a material that is permeable to gas entering or escaping from the cell but essentially impermeable to electrolyte. The gas diffusion layer is adhered to the active layer by a patterned pressure bonding process to provide the catalytic electrode in which the entire gas diffusion area is adhered to the active layer, with areas of relatively high and relatively low adhesion. The electrode has a high overall bond strength, and the permeability of the gas diffusion layer remains high it has been adhered to the active layer to provide excellent high power capability.

Process for making a catalytic electrode and electrochemical cell using the electrode

An apparatus for and a method of feeding powders to a subsequent processing step. In particular, the apparatus includes a first hopper, a first metering brush feed, an intermediate chamber, a second distribution brush, a level sensor, and a supply hopper to deliver powder to a pair of rollers. In one embodiment, the hopper is fitted to the roller diameter to produce a uniform, ribbon or free-standing sheets suitable for air-breathing battery and fuel cell electrodes.

Apparatus for uniform feeding of powders

A composition useful for the fueling and refueling of electrochemical devices is described. The composition comprises an ion-conducting medium such as an electrolyte, and catalyst nanoparticles. Unlike traditional electrodes, such as those typically used in electrolyzers and fuel cells, the inventive composition may be quickly drained from the device and refilled to maintain maximum cell performance. In addition, the electro-catalytic charging composition can be stored as a solid for safe handling; for example in a portable cartridge.

Electro-catalytic recharging composition

An electrochemical battery cell with an oxygen reduction electrode and having improved electrolyte leakage resistance. The cell includes a component, disposed between the oxygen reduction electrode and an air inlet in the cell housing, through or around which air can pass. Upon contact with electrolyte, the component is transformed to form an electrolyte seal.

Air cell with improved leakage resistance

An elongate, generally tubular, air depolarized electrochemical cell ( ) comprising a cathode ( ), including an air cathode assembly ( ), extending about the tubular circumference, and along the tubular length, of the cell ( ), an anode ( ), a separator ( ) between the anode ( ) and the cathode ( ), electrolyte, a top closure member ( ), and a bottom closure member ( ). The cathode assembly ( ) is fixedly held, by a friction fit, in a slot ( ) at the bottom of the cell. The slot can be developed, for example, by inner ( ) and outer ( ) walls of a cathode can ( ), by inner ( ) and outer ( ) walls of a bottom closure member ( ), or by an outer wall ( ) of a cathode can ( ) and an opposing outer wall of a plug ( ) on the interior of the cell. Preferably, bottom closure structure of the cell ( ) and receives a bottom edge portion ( ) of the cathode current collector ( ), and makes electrical contact with the bottom edge portion ( ), preferably at an inner surface ( ) of the cathode current collector. A diffusion member ( ) of the cathode assembly ( ) is preferably compressed as a seal, at the bottom of the cell ( ), between an outer side wall ( ) of the cell and the remainder of the cathode assembly ( ). The diffusion member ( ) is also used at least as an assist in sealing the cell ( ) against electrolyte leakage from the anode cavity ( ) and past the cathode assembly ( ). An embodiment may provide a stop ledge ( ) in grommet ( ) facing a stop groove ( ) in a cathode can ( ). The cathode assembly ( ) can extend into a slot ( ) at an outer edge of the grommet ( ). A top grommet ( ) can have an upwardly extending leg ( A) overlain by a top closure member ( ). The air diffusion member ( ) may control the rate of entry of air to the reaction surface, depending on density of the air diffusion member ( ), whereby the air diffusion member ( ) controls the limiting current of the cell ( ). The air cell ( ) can be free from adhesive bonding the separator ( ) to the cathode assembly ( ). The bottom of the cathode current collector ( ) may be in a bottom slot ( ), in a path of flow of current between a reaction surface and a positive electrode terminal ( ). A method of fabricating cells can including crimping a top washer ( ) and an outer leg ( ) of a top grommet ( ) at the same time, including closing a slot ).

Air depolarized electrochemical cells

An elongate, generally tubular, air depolarized electrochemical cell ( ) comprising a cathode ( ), including an air cathode assembly ( ), extending about the tubular circumference, and along the tubular length, of the cell ( ), an anode ( ), a separator ( ) between the anode ( ) and the cathode ( ), electrolyte, a top closure member ( ), and a bottom closure member ( ). The cathode assembly ( ) is fixedly held, by a friction fit, in a slot ( ) at the bottom of the cell. The slot can be developed, for example, by inner ( ) and outer ( ) wars of a cathode can ( ), by inner ( ) and outer ( ) walls of a bottom closure member ( ), or by an outer wall ( ) of a cathode can ( ) and an opposing outer wall of a plug ( ) on the interior of the cell. Preferably, bottom closure structure of the cell ( ) and receives a bottom edge portion ( ) of the cathode current collector ( ), and makes electrical contact with, the bottom edge portion ( ), preferably at an inner surface ( ) of the cathode current collector. A diffusion member ( ) of the cathode assembly ( ) is preferably compressed as a seal, at the bottom of the cell ( ), between an outer side wall ( ) of the cell and the remainder of the cathode assembly ( ). The diffusion member ( ) is also used at least as an assist in sealing the cell ( ) against electrolyte leakage from the anode cavity ( ) and past the cathode assembly ( ). Various embodiments comprehend a variety of bottom seal members ( ) between the bottom wall ( ) and the electroactive anode material ( ), typically in combination with a bottom slot ( ) receiving the cathode assembly ( ) adjacent an outer side wall ( ) of the bottom closure member ( ).

Bottom seals in air depolarized electrochemical cells

Cathode assembly precursor cathode assembly (,) and elongate air depolarized electrochemical cells (,) made therewith. Cathode assembly precursor comprises a closed-loop elongate cathode current collector (,), and perforations (,) from outer to inner surfaces, and catalystically active carbon extending into the perforations (,). The current collector (,) can be cylindrical and can be free from longitudinal jointing, or can have a longitudinal joint (,), preferably free from overlap of the side wall. The current collector (,) can comprise an imperforate edge region at the top (,) and/or bottom (,), left (,) and/or right (,) edge. The perforations (,) define an open traction of the wall, of about 45 to about 70 percent. Typical cathode assemblies (,) have air diffusion member (,) on the outer surface of the cathode assembly (,). Such air diffusion member (,) typically has thickness of about 0.0025 to 0.005 inch (about 0.06 to about 0.13 mm.), and comprises a reduced thickness endless wrap extending at least 1.5 times, preferably 2 times, or 3 times, about the current collector (,), discouraging transfer of moisture vapor into or out of a cell, discouraging leakage, and controlling air diffusion rate. The diffusion member (,) extends beyond the top edge (,) of the current collector, and is folded in and down about the top edge (,) and inner surface (,) of the cathode assembly (,). The cathode current collector (,) can be mounted on a mandrel (,), the carbon sheet (,) passing through a nip defined between (i) support structure (,) having greater arc radius than the mandrel (,) and (ii) the mandrel (,), and applying force at the nip to consolidate the carbon (,) onto the side wall (,), passing air diffusion material (,) through the nip, and applying force to consolidate the air diffusion material (,) onto the carbon (,). The invention contemplates fabricating an air cathode assembly (,) comprising mounting the current collector (,) on a mandrel (,), defining an arc having a radius smaller than the arc of the cathode current collector (,), mounting the combination mandrel (,) and cathode current collector (,) in a stack (,) of assembly rolls (,A,,B,,C,,D), making a sheet stack of carbon sheets (,B,,C,,D), passing the sheet stack through a nip, and applying force to the stack, reducing thickness of the stack, and passing air diffusion material (,) through the nips and applying force to consolidate the diffusion material (,) onto the carbon (,).

Composite carbon sheet, and electrochemical cells made therewith

This invention pertains to metal-air electrochemical cells wherein one or more air entry ports is located in the bottom of the cathode can, to provide for entry of oxygen-rich air into the cathode can, where the oxygen participates in the electrochemical reaction whereby the cell produces electrical energy. In this invention, extremely small air ports are provided, along with methods of reliably fabricating such small air ports, where a tool impression extends around the port. Generally, the use of an increased number of small air ports distributed over the bottom of the cathode can, opposite the reaction surface of the cathode assembly, wherein the overall open area of the ports is not increased, results in less moisture traversing the air ports, into or out of the cell. Accordingly, moisture loss, or gain, as a function of electrical energy produced, is thereby reduced.

Metal-air cathode can, and electrochemical cell made therewith

The invention provides a metal-air electrochemical cell, having a leak-proof, metal prismatic casing comprising a pair of interfacing interengaging rectangular tray-like casing components, a first substantially rectangular tray-like casing component having a first major surface and contiguous side walls for encompassing a cathode of the cell and a second inverted substantially tray-like casing component having a second major surface and contiguous depending side walls for encompassing an anode of the cell, the side walls of one of the casing components being of a height to facilitate the curling and crimping of an upper portion thereof over a peripheral edge area of the major surface of the other casing component to form a leak-proof, closed prismatic casing.

Prismatic metal-air cells

This invention pertains to metal-air electrochemical cells wherein one or more air entry ports is located in the bottom of the cathode can, to provide for entry of oxygen-rich air into the cathode can, where the oxygen partcicpates in the chemical reaction whereby the cell produces electrical energy. In this invention, multiple small air entry ports are provided. Generally, the use of multiple ports distributed over the bottom of the cathode can, opposite the reaction surface of the cathode assembly, while not increasing the overall open area of the ports, results in an increase in the ratio of the cell limiting current to the rate at which moisture is lost from the cell. Accordingly, moisture loss as a function of electrical energy produced, is less.

Metal-air cathode can and electrochemical cell made therewith

An elongate, generally tubular, air depolarized electrochemical cell (,) comprising a cathode (,), including an air cathode assembly (,), extending about the tubular circumference, and along the tubular length, of the cell (,), an anode (,), a separator (,) between the anode (,) and the cathode (,), electrolyte, a top closure member (,), and a bottom closure member (,). The cathode assembly (,) is fixedly held, by a friction fit, in a slot (,) at the bottom of the cell. The slot can be developed, for example, by inner (,) and outer (,) walls of a cathode can (,), by inner (,) and outer (,) walls of a bottom closure member (,), or by an outer wall (,) of a cathode can (,) and an opposing outer wall of a plug (,) on the interior of the cell. Preferably, bottom closure structure of the cell (,) and receives a bottom edge portion (,) of the cathode current collector (,), and makes electrical contact with the bottom edge portion (,), preferably at an inner surface (,) of the cathode current collector. A diffusion member (,) of the cathode assembly (,) is preferably compressed as a seal, at the bottom of the cell (,), between an outer side wall (,) of the cell and the remainder of the cathode assembly (,). The diffusion member (,) is also used at least as an assist in sealing the cell (,) against electrolyte leakage from the anode cavity (,) and past the cathode assembly (,). Various embodiments comprehend crimping bias in various members at the bottom of the cell (,), to develop the friction fit that fixedly holds the cathode assembly (,) at the bottom of the cell (,). In a can-less embodiment, top (,) and bottom (,) closure members can be separate and distinct from each other, and at least a portion of the air cathode assembly (,) is openly exposed as an outer surface to the ambient environment. A portion of the air diffusion member (,) is compressed in the bottom closure member as a seal.

Elongate air depolarized electrochemical cells

An elongate air depolarized electrochemical cell (,). A grommet (,) closes the top of the cell (,). A seal (,) can extend upwardly into a slot (,) between the grommet (,) and a top closure member (,) such as at the top of a cathode can (,), or a separate top closure member (,). Cathode assembly (,) and separator (,) can extend into the slot (,). The seal is between the grommet (,) and cathode assembly (,), or between grommet (,) and separator (,). or both. The seal can extend upwardly into the slot (,) from an outer surface of the cathode assembly (,), can extend about respective upper edges of the cathode current collector (,), catalyst, and separator (,), and downwardly toward, preferably against or along the inner surface of, the separator (,). The top closure member (,) can be crimped against the grommet (,) at the slot (,), with the cathode assembly (,), and optionally the separator (,), in the slot (,) between the grommet (,) and the top closure (,), thus to provide a liquid-tight crimp seal. The top closure (,) can be crimped first against the grommet (,) at the slot (,), and further crimped against the grommet (,) at a second locus (,) displaced longitudinally from the first crimp. Composition of the seal comprises a microporous polymer (,), preferably polytetrafluoroethylene. Preferred embodiments comprise at least two, preferably at least three, layers of air permeable microporous sheet material, useful for diffusion of air therethrough to the cathode reaction surface (,). The layers are wrapped continuously and without intervening end, to form an outer surface of the cathode assembly (,). Another expression of the invention is a cathode assembly (,), or cathode-separator combination, for use in an elongate air depolarized cell (,). The air permeable sheet material (,), as wrapped about the tubular cathode assembly, is compressed so as to have a compressed thickness less than the uncompressed thickness. The invention still further comprehends an elongate air depolarized cell (,) comprising an anode, a cathode, or cathode-separator combination as described herein, and electrolyte.

Growing community of inventors

Madison, WI, United States of America

Robert B Dopp