This invention relates generally to an alkaline fuel cell and more particularly to a high discharge capacity alkaline fuel cell that operates on an electrolyte containing a dissolved fuel and a reserved solid fuel.
A fuel cell converts chemical energy into electrical energy and some thermal energy by means of a chemical reaction between a fuel reactant (e.g., a hydrogen-containing fuel) and an oxidant (e.g., oxygen). As compared to other energy sources, fuel cells provide advantages that include low pollution, high efficiency, high energy density and simple fuel recharge. Fuel cells can be used in electrochemical engines, portable power supplies for various microelectronic and communication devices, standby power supply facilities, power generating systems, etc. Further, several types of fuel cells utilize renewable resources and provide an alternative to burning fossil fuels to generate power.
The chemical reaction of a fuel cell requires the presence of an electrolyte, electrodes and catalysts. Based on the electrolyte type, the fuel cell is classified as alkaline fuel cell (AFC), phosphoric acid fuel cell (PAFC), molten carbonate fuel cell (MCFC), solid oxide fuel cell (SOFC), and proton exchange membrane or polymer electrolyte membrane fuel cell (PEM-FC). Although PEM-type fuel cell has been a topic of most active R&D efforts during the past decade, other types of fuel cells remain to be commercially viable and have not been ignored. One particularly interesting type is the dissolved fuel alkaline fuel cell (DF-AFC).
As illustrated in
Anode: NaBH4+8O−→NaBO2+6H2O+8e− (1)
The water molecules generated at the anode go into the electrolyte solution, but a portion of water is then used at the cathode. The electrons generated at the anode travel to the cathode side of the fuel cell by passing through an external load that connects the anode and the cathode. Air or oxygen is supplied to the cathode where the electro-reduction of oxygen occurs, resulting in the following chemical reaction:
Cathode: 2O2+4H2O+8e−→8 OH− (2)
Although the fuel is also fully in contact with the cathode, this has not caused any major detrimental effect because the cathode catalyst is not platinum. The overall fuel cell reaction is given by:
Overall: NaBH4+2O2→NaBO2+2H2O (3)
It is of great technological interest to note that eight (8) electrons are generated per fuel molecule consumed. Further, thermodynamic calculations indicate that the theoretical open circuit voltage (OCV) of sch a cell is approximately 1.64 V, which is significantly higher than that achievable by a hydrogen fuel cell (typically 1.2 V). These two features indicate that DF-AFC based on alkali metal borohydride such as NaBH4 potentially have an exceptionally high power density.
However, the catalyst (e.g., Pt) that promotes the direct borohydride oxidation of Eq. (1) also tends to promote the hydrolysis reaction:
Side Reaction: NaBH4+2H2O→NaBO2+4H2 (4)
This side reaction, if not properly controlled, could result in a significant voltage reduction and/or power loss. However, we have discovered that the 4 H2 molecules produced, if captured or constrained by the surface pores of a highly porous anode layer, may be oxidized immediately to produce 8 H+ and 8 electrons via the following reaction:
Reaction of Constrained H2: 4H2→8H++8e−; OCV=1.2 V (5)
Although a lower voltage of 1.2 V is generated, the eight electrons may be recovered if the anode structure is properly designed and the side reaction, Eq. (4) does not proceed too quickly. It is also known that if the concentration of NaBH4 in the electrolyte is low and the electrolyte concentration is high, the side reaction, Eq. (4), is significantly slowed down.
Finkelshtain, et al. (U.S. Pat. No. 6,773,470, Aug. 10, 2004) disclosed a fuel composition for fuel cells. The composition includes a polar solvent such as water, a first portion of a fuel dissolved in the solvent at a saturated concentration, and a second portion of the same fuel suspended in the solvent to serve as a reservoir of fuel which replenishes the fuel as the dissolved portion is consumed. A special advantage of this composition is that this fuel reservoir could keep the fuel cell operate for an extended period of time. However, when the fuel is a hydride such as NaBH4, the fuel composition must also include an additive such as an alkali for stabilizing the fuel. Additionally, this fuel composition for fuel cell has several drawbacks: (1) As indicated in FIG. 1 of U.S. Pat. No. 6,773,470, the fuel is intended for being contained in a designated fuel chamber separate from the electrolyte chamber. These two bulky chambers make the fuel cell structure bulky and complex. (2) The fuel must be dissolved in the solvent at a saturated concentration. Such a high NaBH4 concentration tends to lead to a fast side reaction (hydrolysis of NaBH4), which is a highly undesirable feature. (3) An additive is required to stabilize the fuel. (4) The suspended portion of the fuel, in the form of fine solid particles having excessively high surface area, could be subject to high parasitic (uncontrolled, undesirable) reactions that do not contribute to the provision of electrons to the external load. (5) The fuel solution containing a large proportion of suspended fuel particles, if implemented as an electrolyte between the fuel anode and the air cathode, could significantly reduce the conductivity of OH− ions, thereby adversely affecting the high power performance of an AFC.
Lee, et al. (U.S. Pat. No. 5,599,640, Feb. 4, 1997) disclosed a fuel cell that comprises an aqueous alkaline solution of electrolyte containing a hydrogen-releasing agent (selected from the group consisting of NaBH4, KBH4, LiAlH4, KH and NaH), an oxygen electrode as a cathode and a hydrogen storage alloy electrode as an anode. In this case, ideally, the hydrogen that is generated by a hydrogen-releasing agent should react with the anode metal alloy to form a metal hydride, which serves to chemically retain or store hydrogen. Unfortunately, such a metal hydride forming reaction proceeds at a reasonable speed only at a relatively high temperature. At ambient temperature, a significant portion of hydrogen produced by the hydrogen-releasing agent escapes (without being converted into a hydride) and the fuel is wasted. After a limited number of cycles of repeated metal hydride formation and decomposition steps, the anode tends to become porous, weakened or even broken. This is because re-deposition of metal alloy back to the anode is a random process and normally would not occur to the original spot of the anode. This problem presents a severe system reliability concern for a DF-AFC. Further, since the electrochemical reactions are mediated by the metal alloy and metal hydride at the anode, the reactions are basically similar to those in a hydrogen/oxygen type fuel cell having a theoretical OCV of 1.2 V rather than 1.64 V. This is clearly a disadvantage as compared with the traditional DF-AFC represented by Eq. (1).
It is therefore an object of the present invention to provide an alkaline fuel cell that has a high discharge capacity and a long operating life.
It is another object of the present invention to provide a dissolved fuel alkaline fuel cell (DF-AFC) that has a simple or non-complex configuration.
Another object of the present invention is to provide a reliable DF-AFC that has a relatively high voltage.
These and other objects of the invention are achieved by the fuel cell of the present invention, briefly described as follows:
The present invention provides a dissolved-fuel alkaline fuel cell that comprises four components: a) a fuel anode; b) a first oxygen cathode; c) an electrolyte in ionic contact with the anode and the first cathode, wherein the electrolyte comprises an alkaline solution and a first fuel dissolved in the alkaline solution; and d) a fuel reservoir comprising a solid fuel in physical contact with or in feeding relation to the alkaline solution. The first fuel and/or the solid fuel may be selected from the group consisting of NaBH4, KBH4, LiAlH4, KH, NaH, LiBH4, NaAlH4, (CH3)3NHBH3, NaCNBH3, CaH2, LiH, Na2S2O3, Na2HPO3, Na2HPO2, K2S2O3, K2HPO2, NaCOOH and KCOOH. Actually, all the hydrides and borohydrides of alkali metals, alkaline rare earth metals and their alloys can be used in the present invention. However, NaBH4 and KBH4 are the best choices for serving as a fuel. The fuel reservoir can readily replenish a fuel into the electrolyte-fuel mixture or solution to ensure that the fuel cell continuously generates electrical current without an interruption or a voltage spike. The present fuel cell is simple in design, inexpensive to make, capable of providing a relatively high output voltage, and an exceptionally long service life.
In one preferred embodiment, as illustrated in
The fuel anode 22 is preferably a non-consumable electrode that is electronically conducting so that it may serve two primary functions: (1) as a backing layer or carrier for electro-catalyst 36 that promotes the anode reaction (e.g., Eq. (1) or the like) to produce electrons and (2) as an electron collector through which the produced electrons are transported to an external load (e.g., a bulb 32 in
The oxygen electrode 24 is made of a material selected so that oxygen can be easily engaged in an electro-reduction reaction on its surface. For example, such an electrode may include a carbon paper or cloth, nickel-dispersed carbon paper or cloth, nickel electrode, and the like, which preferably have a double-layer structure consisting of a hydrophilic side interfaced with the electrolyte 26 and a hydrophobic side interfaced with atmosphere. A hydrophobic material such as polytetrafluoroethylene (PTFE, e.g., Teflon®) may be added to one surface of the cathode layer. The oxygen cathode 24 should be permeable to oxygen gas molecules so that oxygen could migrate to the cathode catalyst layer 34 that promotes Eq. (2) to produce the conducting ions OH−. The oxygen cathode should comprise no catalyst that can significantly promote oxidation of the dissolved first fuel at the cathode. Otherwise, this oxidation on the cathode side would reduce the fuel cell efficiency because the electrons produced are wasted.
The electrolyte that can be employed in the present invention may comprise an alkaline solution 26 with pH>7; for example, KOH, NaOH, LiOH, or the like. A chemical species (first fuel) that can react with OH− to produce electrons at the anode is added to the alkaline solution of electrolyte. This fuel may be selected from the group consisting of NaBH4, KBH4, LiAlH4, KH, NaH, LiBH4, (CH3)3NHBH3, NaAlH4, NaCNBH3, CaH2, LiH, Na2S2O3, Na2HPO3, Na2HPO2, K2S2O3, K2HPO3, K2HPO2, NaCOOH, KCOOH, and their combinations. All the hydrides and borohydrides of alkali metals, alkaline rare earth metals and their alloys can be used in the present invention. These materials are salts whose anions have standard reduction potentials in water that are more negative than the standard reduction potential of a hydrogen electrode in water. Preferably, the first fuel is selected from the hydride group consisting of NaBH4, KBH4, LiAlH4, KH, NaH, LiBH4, (CH3)3NHBH3, NaAlH4, NaCNBH3, CaH2 and LiH since they have relatively high reduction potentials. They are also good hydrogen releasing agents that promote anode reactions. The first two, NaBH4 and KBH4, are particularly effective first fuel materials and are the most preferred in the present invention. The fuel may be used preferably in an amount of 0.01 to 50.00% by weight on the basis of the total weight of the alkaline solution of electrolyte. When the amount of the first fuel used is less than 0.01%, the amount of electrons to be produced will be too low for the fuel cell to provide useful power. When the amount of first fuel dissolved is more than the upper limit of the range, the fuel is saturated in the alkaline solution. This tends to promote the side reaction (e.g., Eq (4)), resulting in a lower operating voltage. In order to enhance the ionic conductivity of the electrolyte 26 (when KOH or NaOH is used, for example), LiOH may be added to the alkaline solution of electrolyte in an amount of 0.01 to 0.1% by weight.
It may be noted that the selection of a fuel to be dissolved in the alkaline electrolyte solution is dictated by the types of anode catalyst and cathode catalyst used. The anode catalyst should be selected to promote the anode reaction so that it may proceed at a sufficiently high rate even at ambient temperature or at a temperature not too much higher than the ambient temperature. The cathode catalyst should not promote the anode reaction that produces electrons at the cathode, which electrons otherwise would be wasted. For instance, if NaBH4 is used as a dissolved fuel, platinum is an effective anode catalyst, but platinum should not be used at the cathode side. Several other oxygen-reducing catalysts (e.g., nanometer-scaled Ni and TiO2 particles) may be used instead.
The fuel reservoir 40 may simply be a block or rod of a solid fuel in physical contact with the alkaline solution or in feeding relation thereto. This reservoir fuel may be the same as or different from the first fuel composition and, again, may be selected from the group consisting of NaBH4, KBH4, LiAlH4, KH, NaH, LiBH4, (CH3)3NHBH3, NaAlH4, NaCNBH3, CaH2, LiH, Na2S2O3, Na2HPO3, Na2HPO2, K2S2O3, K2HPO3, K2HPO2, NaCOOH and KCOOH. Again, the first two members are the most preferred. This reservoir is used to replenish the dissolved fuel as the dissolved fuel in the alkaline solution is being consumed. This reservoir may comprise a block or rod of solid fuel (e.g., NaBH4) that remains in constant contact with the alkaline solution and, hence, continuously provides dissolved fuel thereto. The size and shape of this reservoir (a block or rod) may be predetermined so as to provide a desired, constant current or power level. Alternatively, this reservoir may be designed in such a fashion that the rod is fed into the alkaline solution by a desired amount (when needed) to provide a desired but possibly varying current or power level on demand. A simple mechanism may be installed that allows advancing (inserting) or retreating (pulling back) of the rod on demand. Another alternative form of the reservoir comprises a chamber (e.g., simply a plastic bag) that contains a fuel in the powder form. The powder is injected into the electrolyte when needed. This fuel reservoir is capable of keeping the fuel cell operate for an extended period of time. Due to the fact that the cathode active material, O2, is not stored in the fuel cell system, but supplied from the ambient air, this type of electrochemical cell has a very high power density.
Schematically shown in
Another preferred embodiment of the present invention, schematically shown in
Another attractive design for a unit cell with a high-current output is schematically shown in
The dissolve-fuel alkaline fuel cell of the present invention has a higher electrochemical reaction rate than those of the prior art fuel cells. It can operate at room temperature or slightly above to produce a large amount of energy due to its high energy density of 6,200 Ah/kg or more (for NaBH4 or KBH4). With an uninterrupted and convenient supply of fuel through the electrolyte from a reservoir to the anode and unlimited supply of oxygen from open air to the oxygen electrode, the cell can produce electric current continuously for an exceptionally long period of time.
The present invention is further illustrated in the following examples. The examples are presented for illustrative purposes only and should not be construed as limiting the invention, which is properly defined by the claims.
An aqueous solution containing 1 gram of NaBH4 in 500 cc of 6M KOH was used. A carbon paper coated with platinum-carrying carbon particles was used as an anode, with dimensions of approximately 10 mm×10 mm×1 mm. This Pt/C anode was made by dispersing 5% by weight of platinum in VULCAN XC-72 (acquired from E-TEK; a carbon black). The oxygen cathode was prepared by coating an appropriate amount of nickel powder to one side of a carbon paper and coating some Teflon (or polytetrafluoroethylene, a hydrophobic material that repels water) powder to the opposite side. A unit cell like the one shown in
Three samples similar to that used in Example 1 were prepared, but each containing 1 gram of KBH4 as a dissolved fuel and with no fuel reservoir (Sample D), with a fuel reservoir in the form of a solid KBH4 rod (1 gram), and with a fuel reservoir in the form of a solid KBH4 rod (2 grams), respectively. Each fuel cell sample was discharged at a discharge current of 100 mA. In both Samples E and F, the KBH4 rod was in constant contact with the alkaline solution.
It may be noted that the electrochemical reactions involved in the dissolved-fuel alkaline fuel cell produce a by-product such as NaBO2, which is a solid. When the amount of NaBO2 in the electrolyte becomes excessive, resulting in a significantly lower ionic conductivity, the electrolyte must be replaced with a fresh amount of alkaline solution. This can be advantageously accomplished by retreating the fuel reservoir and allowing the dissolved fuel to be fully utilized. Fortunately, alkaline solutions such as KOH are the least expensive electrolyte among all the electrolytes used in all current fuel cell types.