Reveo, Inc.

Reves, Inc.

Wayne Yao

Tsepin Tsai

Sadeg Mustafa Faris

Muguo Chen

Yuen-Ming Chang

Thomas J Legbandt

Lin-Feng Li

William F Morris

Michael Rabin

George Tzeng

Karen Tom

Flat plate fuel cells, particularly air-depolarized cells, are stacked and electrically interconnected into a battery structure with a connector block and tray. The anode and cathode elements of each cell are provided with extending terminal conductor elements (e.g., banana plugs), preferably extending in downward &ldquo;U&rdquo; shaped configuration from the upper ends of the anode and cathode elements respectively. The connector block comprises a series of conductive apertures, positioned and sized to accommodate the terminal conductor elements of the electrodes therein and the connector block comprises electrical interconductive elements to electrically connect- the electrodes of the stacked cells in a desired electrical interconnection (serial, parallel and mixed serial and parallel segments). The interconnection between terminal conductor elements and the respective apertures further serves to support and orient the cells in a minimal volume and permits selective rapid cell removal for replacement or servicing. The cells are also provided with keyed members for keyed interlocking with a support tray having co-fitting keying elements to provide full structural integrity for the stacked cells. Lateral end elements extend between the connector block and support tray to complete an open enclosure and provide a support base for air circulating devices such as fans. Air is circulated through a duct defined by the block and between the fuel cells.

Fuel cell support and electrical interconnector

A highly conductive polymer based solid gel membrane is disclosed. The membrane is especially well suited for use in such electrochemical devices as, for example, aluminum/air, zinc/air, Zn/MnO , Ni/Cd and hydrogen fuel cells, as well as in electrochromic devices such as smart windows and flat panel displays. In accordance with the principles of the invention, anion- and cation-conducting membranes are formed. The gel composition of the membrane contains the ionic species within its solution phase such that the species behaves as in a liquid electrolyte, while at the same time, the solid gel composition prevents the solution phase from diffusing into the device. Methods of forming polymer based solid gel membranes of the present invention are also disclosed.

Solid gel membrane

An energy conversion system, comprising: a reservoir container including at least two chambers of inversely variable volume for respectively storing a quantity of fuel and receiving a quantity of exhaust; a means for decreasing the volume of the first chamber while concurrently increasing the volume of the second chamber; at least one energy conversion device; first means for communicating fuel between the at least one energy conversion device and a first of the chambers in the reservoir container; and second means for communicating exhaust between the at least one energy conversion device and a second of the chambers in the reservoir container. The reservoir container may be transported to a recharging/refilling station or recharged in-situ. A particular application for metal-air fuel cell power systems is shown and described.

Fuel containment and recycling system

Improved metal-air fuel cell battery systems having metal-fuel realized in the form of metal-fuel tape cartridges and metal-fuel cards, which can be either manually or automatically inserted within the power generation bay of the system. In order to produce a range of output voltages, the metal-fuel tape has a plurality of electrically-isolated metal-fuel tracks and the metal-fuel cards have a plurality of electrically-isolated metal-fuel strips. An output voltage configuration subsystem is provided for configuring the voltages produced by the individual cells to produce a desired output. A subsystem is provided for detecting oxide formation on the metal-fuel tracks and strips so that only metal-fuel that has been oxidized is reduced during recharging operations. A subsystem is also provided for controlling the flow of oxygen into the power generation head in order to control the power output from the system.

Metal-air fuel cell battery system employing metal-fuel cards

A solid-state hydroxide (OH ) conductive membrane provides up to five times higher ionic conductivity and surface oxygen exchange rate than conventional MIEC membranes, while operating at significantly lower temperatures and providing reduced overall system cost. The hydroxide conductive membrane utilizes a porous ceramic backbone, pores of which are injected with an electrolyte. A catalyst is provided as discrete layers disposed at the anode and cathode. The membrane of the present invention may be utilized in combination with an external voltage source to drive the oxygen generating reaction. Alternatively, the pores may be metallized and a pressure gradient utilized to drive the reaction. The membrane thus provides discrete materials to provide ionic conduction, electronic conduction, and structural support.

Oxygen separation through hydroxide-conductive membrane

In an air-metal fuel cell battery (FCB) system, wherein a movable cathode structure is mounted within a 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 the movable cathode structure. In illustrative embodiments, the movable cathode structure is realized as a rotatable cathode cylinder, and a transportable cathode belt. 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. During system operation, the metal-fuel tape and/or the ionically-conductive medium are wetted in order create sufficient surface tension, and thus sufficient hydrostatic forces, between the metal-fuel tape and ionically-conductive medium and between the ionically-conductive medium and the movable cathode structure, to enable the movable cathode structure, ionically-conductive medium and metal-fuel tape to move at substantially the same velocity at points of contact therebetween while only one or these three moving system components are being actively driven by a transport mechanism. By virtue of the present invention, it is possible to transport the moving components of the FCB system using a various types of low power devices including, for example, miniature electrical and spring-driven motors, while substantially reducing the likelihood of damage thereto during system operation.

METAL-AIR FUEL CELL BATTERY SYSTEM EMPLOYING HYDROSTATIC FORCES TO ENABLE SIMULTANEOUS TRANSPORT OF METAL-FUEL TAPE, MOVABLE CATHODE STRUCTURE, AND IONICALLY-CONDUCTIVE MEDIUM THERETHROUGH DURING SYSTEM OPERATION

Improved electro-chemical power generation devices (e.g., metal-air fuel cell battery devices) having metal-fuel realized in the form of a metal-fuel card including a plurality of electrically-isolated metal-fuel elements (e.g., strips) disposed on the surface of substantially rigid and planar non-electrically-conductive substrate. The metal-fuel elements are in electrical contact with the anode contacting elements of the power generation device when the metal-fuel card is spatially registered to anode contacting elements of the electro-chemical power generation device. In another aspect of the present invention, an aperture formed in the substrate provides electrical contact between the metal-fuel element disposed on the first side of the substrate and the anode contacting element disposed on the second side of the substrate when the metal-fuel card is spatially registered to the anode contacting element.

Metal-fuel card with a plurality of metal-fuel elements and corresponding contact apertures, and electro-chemical electric power generation devices employing same

An electrochemical cathode includes a porous metal foam substrate, formed with a network of interconnected pores. An active layer and a hydrophobic microporous gas diffusion layer are both disposed on one or more surfaces of the metal foam substrate. The metal foam substrate serves as the current collector of the cathode. The microporous layer is a plastic material such as a fluoropolymer (i.e., PTFE). The cathode also includes a particulate microstructure reinforced by relatively strong bonding provided by sintering a polymeric binder within the three-dimensional interconnected porosity of the metal foam substrate. The reactive layers are preferably fabricated from the same material as binder. This advantageously enables a single roll pressing operation to simultaneously impregnate the binder into the substrate and form the reactive layers thereon.

Electrochemical electrode for fuel cell

In an air-metal fuel cell battery (FCB) system, wherein metal-fuel tape, the ionically-conductive medium and the cathode structures are transported at substantially the same velocity at the locus of points at which the ionically-conductive medium contacts the moving cathode structure and the moving metal-fuel tape during discharging and recharging modes of operation. In a first generalized embodiment of the present invention, the ionically-conductive medium is realized as an ionically-conductive belt, and the metal-fuel tape, ionically-conductive belt, and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing belt contacts the metal-fuel tape and the cathode structure during system operation. In a second generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state (e.g. gelatinous) film layer integrated with the metal-fuel tape, and the metal-fuel tape, ionically-conductive film layer and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing film layer contacts the metal-fuel tape and the cathode structure during system operation. In a third generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state film layer integrated with the movable cathode structure, and the metal-fuel tape, ionically-conductive film layer and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing film layer contacts the metal-fuel tape and the cathode structure during system operation. By transporting the movable cathode structure, ionically contacting medium and metal-fuel tape within the system as described above, generation of frictional forces among such structures are minimized during system operation, and thus the damage to the cathode structure and metal-fuel tape is substantially reduced.

Cathode belt structure for use in a metal-air fuel cell battery system and method of fabricating the same

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.

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

Improved metal-air fuel cell battery systems having metal-fuel realized in the form of substantially planar metal-fuel cards of rigid construction, which can be either manually or automatically inserted within the power generation bay of the system. The power generation bay includes at least one electrically-conductive cathode element supported by a cathode support structure in a stationary position with respect to the cathode support structure, and at least one electrically-conductive anode-contacting element supported by an anode contacting structure in a stationary position with respect to the anode contacting structure. In order to produce a range of output voltages, the power generation bay includes a plurality of cells comprising cathode elements spatially arranged with anode contacting elements, and each metal-fuel card has a plurality of electrically-isolated metal-fuel strips that are spatially arranged with these cells when the metal-fuel card is inserted to the power generation bay. An output voltage configuration subsystem is provided for configuring the voltages produced by the individual cells to produce a desired output. A subsystem is provided for detecting oxide formation on the metal-fuel strips so that only metal-fuel that has been oxidized is reduced during recharging operations. A subsystem is also provided for controlling the flow of oxygen into the power generation head in order to control the power output from the system.

Metal-air fuel cell battery system employing substantially planar metal-fuel cards of rigid construction insertable into a power generation bay of the system

In an air-metal fuel cell battery (FCB) system, wherein metal-fuel tape, the ionically-conductive medium and the cathode structures are transported at substantially the same velocity at the locus of points at which the ionically-conductive medium contacts the moving cathode structure and the moving metal-fuel tape during discharging and recharging modes of operation. In a first generalized embodiment of the present invention, the ionically-conductive medium is realized as an ionically-conductive belt, and the metal-fuel tape, ionically-conductive belt, and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing belt contacts the metal-fuel tape and the cathode structure during system operation. In a second generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state film layer integrated with the metal-fuel tape. In a third generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state film layer integrated with the movable cathode structure. By transporting the movable cathode structure, ionically contacting medium and metal-fuel tape within the system as described above, generation of frictional forces among such structures are minimized during system operation, and thus the damage to the cathode structure and metal-fuel tape is substantially reduced.

Ionically-conductive belt structure for use in a metal-air fuel cell battery system and method of fabricating the same

In an air-metal fuel cell battery (FCB) system, wherein metal-fuel tape, the ionically-conductive medium and the cathode structures are transported at substantially the same velocity at the locus of points at which the ionically-conductive medium contacts the moving cathode structure and the moving metal-fuel tape during discharging and recharging modes of operation. In a first generalized embodiment of the present invention, the ionically-conductive medium is realized as an ionically-conductive belt, and the metal-fuel tape, ionically-conductive belt, and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing belt contacts the metal-fuel tape and the cathode structure during system operation. In a second generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state (e.g. gel-like) film layer integrated with the metal-fuel tape, and the metal-fuel tape, ionically-conductive film layer and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing film layer contacts the metal-fuel tape and the cathode structure during system operation. In a third generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state film layer integrated with the movable cathode structure, and the metal-fuel tape, ionically-conductive film layer and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing film layer contacts the metal-fuel tape and the cathode structure during system operation. By transporting the movable cathode structure, ionically contacting medium and metal-fuel tape within the system as described above, generation of frictional forces among such structures are minimized during system operation, and thus the damage to the cathode structure and metal-fuel tape is substantially reduced.

Cathode cylinder for use in metal-air fuel cell battery systems and method of fabricating the same

In an air-metal fuel cell battery (FCB) system, wherein metal-fuel tape, the ionically-conductive medium and the cathode structures are transported at substantially the same velocity at the locus of points at which the ionically-conductive medium contacts the moving cathode structure and the moving metal-fuel tape during discharging and recharging modes of operation. In a first generalized embodiment of the present invention, the ionically-conductive medium is realized as an ionically-conductive belt, and the metal-fuel tape, ionically-conductive belt, and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing belt contacts the metal-fuel tape and the cathode structure during system operation. In a second generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state (e.g. gelatinous) film layer integrated with the metal-fuel tape. In a third generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state film layer integrated with the movable cathode structure. By transporting the movable cathode structure, ionically contacting medium and metal-fuel tape within the system as described above, generation of frictional forces among such structures are minimized during system operation, and thus the damage to the cathode structure and metal-fuel tape is substantially reduced.

A polymer-based electrolyte composition having excellent film-forming properties, flexibility, mechanical strength and high hydroxide conductivity is disclosed. The composition comprises an organic polymer having an alkyl quaternary ammonium salt structure; a nitrogen-containing, heterocyclic quaternary ammonium salt; and a metal hydroxide salt. In a preferred embodiment, the composition is cast in the form of a film that is suitable for use as an ion-conducting or other specialty membrane in a power source, such as for example an alkaline battery or fuel cell, that relies on hydroxide anion transport for its operation.

Growing community of inventors

Bergenfield, NJ, United States of America

Wayne Yao