Patent Grant
8911910
The present invention relates to a rechargeable electrochemical cell system.
Electrochemical cells are well known. An electrochemical cell includes an anode or fuel electrode at which a fuel oxidation reaction takes place, a cathode or oxidant electrode at which an oxidant reduction reaction takes place, and an ionically conductive medium for supporting the transport of ions. In some metal-air cells, such as those disclosed in U.S. patent application Ser. No. 12/385,489 (published as U.S. Patent Application Publication No. 2009/0284229) and Ser. No. 12/901,410 (published as U.S. Patent Application Publication No. 2011/0086278), both of which are incorporated herein by reference, the fuel electrode comprises a plurality of scaffolded electrode bodies, on which metal fuel is reduced and electrodeposited.
Electrochemical cell systems may comprise a plurality of electrochemical cells. In some such electrochemical cell systems, the fuel electrode of the first cell may be coupled to a first terminal, the oxidant electrode of each cell within the cell system may be connected to the fuel electrode of the subsequent cell, and the oxidant electrode of the last cell in the series may be connected to a second terminal. Thus, a potential difference is created within each individual cell, and because these cells are coupled in series, a cumulative potential difference is generated between the first and second terminals. These terminals connect to a load L, creating a potential difference that drives current.
Among other things, the present application endeavors to provide a more efficient and effective architecture for recharging and discharging electrochemical cells and electrochemical cell systems.
According to an embodiment of the present disclosure, an electrochemical cell includes a fuel electrode comprising a series of permeable electrode bodies arranged in spaced apart relation, an oxidant electrode spaced apart from the fuel electrode, and a charging electrode selected from the group consisting of (a) the oxidant electrode, (b) a third electrode spaced from the fuel electrode and the oxidant electrode, and (c) a portion of the fuel electrode. The electrochemical cell further includes an ionically conductive medium contacting the electrodes, and a charge/discharge controller coupled to a plurality of the electrode bodies of the fuel electrode. The charge/discharge controller is configured to apply an electrical current between the charging electrode and at least one of the permeable electrode bodies, with the charging electrode functioning as an anode and the at least one permeable electrode body 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 at least one permeable electrode body, so that said electrodeposition causes growth of the metal fuel among the permeable electrode bodies, with the electrodeposited metal fuel establishing an electrical connection between the permeable electrode bodies. The charge/discharge controller is configured to selectively apply the electrical current to a different number of said permeable electrode bodies, each functioning as a cathode, based on at least one input parameter so as to adjust a rate and density of the growth of the electrodeposited metal fuel.
According to another embodiment of the present disclosure, a method of recharging an electrochemical cell is provided. The electrochemical cell includes a fuel electrode comprising a series of permeable electrode bodies arranged in spaced apart relation, an oxidant electrode spaced apart from the fuel electrode, and a charging electrode selected from the group consisting of (a) the oxidant electrode, (b) a third electrode spaced from the fuel electrode and the oxidant electrode, and (c) a portion of the fuel electrode. The electrochemical cell further includes an ionically conductive medium contacting the electrodes, and a charge/discharge controller coupled to a plurality of the electrode bodies of the fuel electrode. The charge/discharge controller is configured to apply an electrical current between the charging electrode and at least one of the permeable electrode bodies, with the charging electrode functioning as an anode, and the at least one permeable electrode body 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 at least one permeable electrode body, so that said electrodeposition causes growth of the metal fuel among the permeable electrode bodies with the electrodeposited metal fuel establishing an electrical connection between the permeable electrode bodies. The charge/discharge controller is configured to selectively apply the electrical current to a different number of said permeable electrode bodies based on at least one input parameter so as to adjust a rate and density of the growth of the electrodeposited metal fuel.
The method includes selecting, based on the at least one input parameter, between a higher density progressive growth mode and a higher rate growth mode. The method further includes charging the electrochemical cell based on the selected one of the higher density progressive charge mode and the higher rate growth mode. In the higher density progressive growth mode, said charging comprises applying the electrical current to a terminal one of the permeable electrode bodies, with the charging electrode functioning as the anode and the terminal electrode body functioning as the cathode, such that the reducible metal fuel ions are reduced and electrodeposited as metal fuel in oxidizable form on the terminal permeable electrode body. The electrodeposition causes 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 each subsequent permeable electrode body with said reduction and deposition occurring on each subsequent permeable electrode body upon establishment of said electrical connection. In the higher rate growth mode, said charging comprises applying the electrical current simultaneously to a plurality of said electrode bodies, with the charging electrode functioning as the anode and each of the plurality of electrode bodies functioning as cathodes, 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. The method further includes disconnecting the electrical current to discontinue the charging.
Other objects, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
In an embodiment, the fuel electrode 12 is a metal fuel electrode that functions as an anode when the cell 10 operates in discharge, or electricity generating, mode, as discussed in further detail below. In an embodiment, the fuel electrode 12 may comprise a plurality of permeable electrode bodies 12a-d, such as screens that are made of any formation able to capture and retain, through electrodepositing, or otherwise, particles or ions of metal fuel from an ionically conductive medium that circulates in the cell 10, as discussed in further detail below. Components of the cell 10, including for example, the fuel electrode 12, the permeable electrode bodies 12a-d thereof, and the oxidant electrode 14, may be of any suitable construction or configuration, including but not limited to being constructed of Nickel or Nickel alloys (including Nickel-Cobalt, Nickel-Iron, Nickel-Copper (i.e. Monel), or superalloys), Copper or Copper alloys, brass, bronze, or any other suitable metal. In an embodiment, a catalyst film may be applied to some or all of the permeable electrode bodies 12a-d and/or the oxidant electrode 14, and have a high surface material that may be made of some of the materials described above. In an embodiment, the catalyst film may be formed by techniques such as thermal spray, plasma spray, electrodeposition, or any other particle coating method.
The fuel may be a metal, such as iron, zinc, aluminum, magnesium, or lithium. By metal, this term is meant to encompass all elements regarded as metals on the periodic table, including but not limited to alkali metals, alkaline earth metals, lanthanides, actinides, and transition metals, either in atomic, molecular (including metal hydrides), or alloy form when collected on the electrode body. However, the present invention is not intended to be limited to any specific fuel, and others may be used. The fuel may be provided to the cell 10 as particles suspended in the ionically conductive medium. In some embodiments, a metal hydride fuel may be utilized in cell 10.
The ionically conductive medium may be an aqueous solution. Examples of suitable mediums include aqueous solutions comprising sulfuric acid, phosphoric acid, triflic acid, nitric acid, potassium hydroxide, sodium hydroxide, sodium chloride, potassium nitrate, or lithium chloride. The medium may also use a non-aqueous solvent or an ionic liquid. In the non-limiting embodiment described herein, the medium is aqueous potassium hydroxide. In an embodiment, the ionically conductive medium may comprise an electrolyte. For example, a conventional liquid or semi-solid electrolyte solution may be used, or a room temperature ionic liquid may be used, as mentioned in U.S. patent application Ser. No. 12/776,962 (published as U.S. Patent Application Publication No. 2010/0285375), the entirety of which is incorporated herein. In an embodiment where the electrolyte is semi-solid, porous solid state electrolyte films (i.e. in a loose structure) may be utilized.
The fuel may be oxidized at the fuel electrode 12 when the fuel electrode 12 is operating as an anode, and an oxidizer, such as oxygen, may be reduced at the oxidant electrode 14 when the oxidant electrode 14 is operating as a cathode, which is when the cell 10 is connected to a load L and the cell 10 is in discharge or electricity generation mode, as discussed in further detail below. The reactions that occur during discharge mode may generate by-product precipitates, e.g., a reducible fuel species, in the ionically conductive medium. For example, in embodiments where the fuel is zinc, zinc oxide may be generated as a by-product precipitate/reducible fuel species. The oxidized zinc or other metal may also be supported by, oxidized with or solvated in the electrolyte solution, without forming a precipitate (e.g. zincate may be a dissolved reducible fuel species remaining in the fuel). During a recharge mode, which is discussed in further detail below, the reducible fuel species, e.g., zinc oxide, may be reversibly reduced and deposited as the fuel, e.g., zinc, onto at least a portion of the fuel electrode 12 that functions as a cathode during recharge mode. During recharge mode, either the oxidant electrode 14 or a separate charging electrode 70 (which may be of similar construction or configuration as permeable electrode bodies 12a-d in some embodiments), and/or another portion of the fuel electrode 12, as described below, functions as the anode. The switching between discharge and recharge modes is discussed in further detail below.
The electrode holder 16 defines a cavity 18 in which the fuel electrode 12 is held. The electrode holder 16 also defines an inlet 20 and an outlet 22 for the cell 10. The inlet 20 is configured to allow the ionically conductive medium to enter the cell 10 and/or recirculate through the cell 10. The inlet 20 may be connected to the cavity 18 via an inlet channel 24, and the outlet 22 may be connected to the cavity 18 via an outlet channel 26. As illustrated in
For each cell 10, a permeable seal member 17 may be bonded between sealing surfaces on the electrode holders 16 and/or the cover 19, as appropriate, to enclose at least the fuel electrode 12 in the cavity 18. The seal member 17 also covers the inlet and outlet channels 24, 26. The seal member 17 is non-conductive and electrochemically inert, and is preferably designed to be permeable to the ionically conductive medium in the orthogonal direction (i.e., through its thickness), without permitting lateral transport of the ionically conductive medium. This enables the ionically conductive medium to permeate through the seal member 17 for enabling ion conductivity with the oxidant electrode 14 on the opposing side to support the electrochemical reactions, without “wicking” the ionically conductive medium laterally outwardly from the cell 10. A few non-limiting examples of a suitable material for the seal member 17 are EPDM and TEFLON®.
In the illustrated embodiment, the cavity 18 has a generally rectangular, or square, cross-section that substantially matches the shape of the fuel electrode 12. The cavity 18 may be connected to the inlet channel 24 by a plurality of inlets 34 so that when the ionically conductive medium and precipitates or reducible fuel species enter the cavity 18, the ionically conductive medium and fuel are distributed along a side of the fuel electrode 12. In some embodiments, one side of the cavity 18, specifically, the side of the cavity 18 that is connected to the inlet channel 24, may include a plurality of fluidization zones, such as is described in U.S. patent application Ser. No. 12/901,410, incorporated herein in its entirety by reference. In other embodiments, the ionically conductive medium may enter the cavity 18 through a diffuser, such as is described in U.S. Provisional Patent Application No. 61/301,377, now converted into U.S. patent application Ser. No. 13/019,923 (published as U.S. Patent Application Publication No. 2011/0189551), each of which is also incorporated herein in its entirety by reference. In various embodiments, the ionically conductive medium may flow in parallel or in series through a plurality of cells 10. In some embodiments, the ionically conductive medium may utilize a combination of parallel and series flows. Furthermore, in various embodiments the ionically conductive medium may flow at a varying rate, and even may flow intermittently (i.e. static for a time) during operation of the one or more cells 10.
As illustrated in
The spacers 40 are non-conductive and electrochemically inert so they are inactive with regard to the electrochemical reactions in the cell 10. The spacers 40 are preferably sized so that when they are connected to the electrode holder 16, the spacers 40 are in tension, which allows the spacers 40 to press against the fuel electrode 12, or one of the electrode bodies 12a-12c, so as to hold the fuel electrode 12 or bodies thereof in a flat relation relative to the electrode holder 16. The spacers 40 may be made from a plastic material, such as polypropylene, polyethylene, noryl, fluoropolymer, etc. that allows the spacers 40 to be connected to the electrode holder 16 in tension. In various embodiments, the spacers 40 may be attached together by techniques such as (but not limited to) thermal bonding, chemical bonding, or ultrasonic welding/bonding
In the embodiment illustrated in
Once the spacers 40 have been connected to the electrode holder 16 via the end portions 46, the flow lanes 42 are defined across the cavity 18 of the electrode holder 16. The spacers 40 are configured to essentially seal off one flow lane 42a from an adjacent flow lane 42b, that is separated by one of the spacers 40 so that the ionically conductive medium is guided to generally flow in substantially one direction. Specifically, the ionically conductive medium may generally flow in a first direction FD across the fuel electrode 12, from the inlet channel 24 to the outlet channel 26. A suitable pressure drop is generated between the inlet channel 24 and the inlets 34 so that the ionically conductive medium may flow across the cavity 18 and to the outlet channel 26, even when the cell 10 is oriented such that the flow is substantially upward and against gravity. In an embodiment, the ionically conductive medium may also permeate through the fuel electrode 12, or an individual permeable electrode body 12a-12d, in a second direction SD and into a flow lane that is on the opposite side of the fuel electrode 12 or permeable electrode body 12a-12d.
As illustrated in the embodiment of
The oxidant electrode 14 functions as a cathode when the oxidant electrode 14 is connected to the external load L and the cell 10 operates in discharge mode. When functioning as a cathode, the oxidant electrode 14 is configured to receive electrons from the external load L and reduce an oxidizer that contacts the oxidant electrode 14. The oxidizer may be any species of the oxidant available for oxidation at the charging electrode. For example, the species may be a free ion, or an ion bonded to or coordinated with other ions or constituents in the ionically conductive medium. In an embodiment, the oxidant electrode 14 comprises an air breathing electrode and the oxidizer comprises oxygen in the surrounding air.
The oxidizer may be delivered to the oxidant electrode 14 by a passive transport system. For example, where oxygen present in ambient air is the oxidizer, simply exposing the oxidant electrode 14 to ambient air via openings in the cell, such as the openings that are provided by grooves 54 in the cover 19 and grooves 56 in the electrode holder 16 provided in the center of the electrochemical cell system 100, may be sufficient to allow diffusion/permeation of oxygen into the oxidant electrode 14. Other suitable oxidizers may be used and embodiments described herein are not limited to the use of oxygen as the oxidizer. A peripheral gasket 15 may be positioned between the periphery of the oxidant electrode 14 and the cover 19 or electrode holder 16, as appropriate, to prevent the ionically conductive medium from leaking around the oxidant electrode 14 and into the area in the grooves 54, 56 for air exposure.
In other embodiments, a pump, such as an air blower, may be used to deliver the oxidizer to the oxidant electrode 14 under pressure. The oxidizer source may be a contained source of oxidizer. In an embodiment, the oxygen may be recycled from the cell 10, such as is disclosed in U.S. patent application Ser. No. 12/549,617 (published as U.S. Patent Application Publication No. 2010/0119895), incorporated in its entirety herein by reference. Likewise, when the oxidizer is oxygen from ambient air, the oxidizer source may be broadly regarded as the delivery mechanism, whether it be passive or active (e.g., pumps, blowers, etc.), by which the air is permitted to flow to the oxidant electrode 14. Thus, the term “oxidizer source” is intended to encompass both contained oxidizers and/or arrangements for passively or actively delivering oxygen from ambient air to the oxidant electrode 14.
Electricity that can be drawn by the external load L is generated when the oxidizer at the oxidant electrode 14 is reduced, while the fuel at the fuel electrode 12 is oxidized to an oxidized form. The electrical potential of the cell 10 is depleted once the fuel at the fuel electrode 12 is entirely oxidized or oxidation is arrested due to passivation of the fuel electrode. A portion of the switching system 60 may be positioned in between the oxidant electrode 14 and the load L so that the oxidant electrode 14 may be connected and disconnected from the load L, as desired. Again, more details about the switching system 60, and the electrical configuration thereof, is provided below.
To limit or suppress hydrogen evolution at the fuel electrode 12 during discharge mode and during quiescent (open circuit) periods of time, salts may be added to retard such a reaction. Salts of stannous, lead, copper, mercury, indium, bismuth, or any other material having a high hydrogen overpotential may be used. In addition, salts of tartrate, phosphate, citrate, succinate, ammonium or other hydrogen evolution suppressing additives may be added. In an embodiment, metal fuel alloys, such as Al/Mg may be used to suppress hydrogen evolution. Other additives may also or alternatively be added to the ionically conductive medium, including, but not limited to additives which enhance the electrodeposition process of the metal fuel on the fuel electrode 12, such as is described in U.S. Provisional Patent Application 61/304,928, now converted into U.S. patent application Ser. No. 13/028,496, incorporated in its entirety herein by reference. After the fuel in the cell 10 has been entirely oxidized, or whenever it is desirable to regenerate the fuel within the cell 10 by reducing oxidized fuel ions back to fuel, the fuel electrode 12 and the oxidant electrode 14 may be decoupled from the external load L and coupled to a power supply PS. As noted above, such connections may be made, for example, with the use of the switching system 60 and the terminal selector system 62.
The power supply PS is configured to charge the cell 10 by applying a potential difference between the fuel electrode 12 and the oxidant electrode 14 such that the reducible species of the fuel is reduced and electrodeposited onto at least one of the permeable electrode bodies 12a-12d and the corresponding oxidation reaction takes place at the oxidant electrode 14, which is typically oxidation of an oxidizable species to evolve oxygen, which may be off-gassed from the cell 10. In an embodiment wherein oxygen is the oxidant, oxygen ions in an aqueous electrolytic solution are oxidized. The oxygen ions may be available from an oxide of the fuel (e.g., ZnO when zinc is the fuel), hydroxide ions (OH−), or water molecules (H2O). As described in detail in U.S. patent application Ser. No. 12/385,489, which has been incorporated herein by reference, in an embodiment only one of the permeable electrode bodies, such as 12a, is connected to the power supply PS so that the fuel reduces onto the permeable electrode body and progressively grows to and on the other permeable electrode bodies 12b-12d, one by one. The switching system 60 may control how the permeable electrode bodies 12a-12d and the oxidant electrode 14 participate in the electrochemical reactions of the cell, as is described in greater detail below.
In the embodiment described above with respect to
It is also possible in any of the embodiments of the invention to apply the cathodic potential to any or all of the electrode bodies 12a-12d of the fuel electrode 12, rather than to just one to produce body-by-body progressive growth. Progressive growth emanating from one terminal is advantageous because it provides more density of the electrodeposited fuel. Specifically, the growth in the previously connected electrode bodies continues as each subsequent body is connected by the progressing growth. This and other advantages are discussed in greater detail in U.S. patent application Ser. No. 12/385,489, which has been incorporated herein by reference. With all the electrode bodies subject to the same potential, the growth will only occur until a short occurs between the charging electrode, which is the oxidant electrode 14 in the embodiment of
The embodiments illustrated in
Returning to
The cells 10 illustrated in
In an embodiment of operation, the fuel electrode 12, which already has metal fuel deposited thereon, is connected to the load L and the oxidant electrode 14 is connected to the load L. The ionically conductive medium enters the inlet 20 under positive pressure and flows through the inlet channel 24, the inlets 34 of the cavity 18, and into the flow lanes 42. The ionically conductive medium flows across the permeable electrode bodies 12a-12d in the flow lanes 42 defined by the elongated middle portions 22 of the spacers 40. The ionically conductive medium may also permeate through the permeable electrode bodies 12a-12d of the fuel electrode 12. The ionically conductive medium simultaneously contacts the fuel electrode 12 and the oxidant electrode 14, thereby allowing the fuel to oxidize and conduct electrons to the load L, while the oxidizer is reduced at the oxidant electrode 14 via the electrons that are conducted to the oxidant electrode 14 by the load L. After the ionically conductive medium has passed through the flow lanes 42, the medium flows out of the cavity 18 via the outlets 36 of the cavity 18, through the outlet channel 24, and out the outlet 22 of the cell 10.
When the potential of the cell 10 has been depleted or when it is otherwise desirable to recharge the cell 10, the fuel electrode 12 is connected to the negative terminal of the power supply PS and the charging electrode, which may be the oxidant electrode 14 or the separate charging electrode 70, is connected to the positive terminal of the power supply PS. Such connections may again be through the switching system 60, discussed below. In the charging or recharge mode, a cathode portion of the fuel electrode 12 becomes the cathode and an anode portion of the fuel electrode 12 and/or the charging electrode 14, 70 becomes the anode, as is described in greater detail below. By providing electrons to a cathode portion of the fuel electrode 12, fuel ions may reduce into fuel and redeposit onto the permeable electrode bodies 12a-12d, as is described in greater detail below, while the ionically conductive medium circulates through the cell 10 in the same manner as described above with respect to the discharge mode.
The flow lanes 42 provide directionality and distribution of the ionically conductive medium across the fuel electrode 12. The flow lanes 42 may also prevent the particulates from settling and/or covering the electrodes. When the cell 10 is in charging mode, the improved distribution of the particulates across the fuel electrode 12 allows for a more uniform deposition of the reduced fuel onto the fuel electrode 12, which improves the density of the fuel on the fuel electrode 12, and increases the capacity and energy density of the cell 10, thereby enhancing the cycle-life of the cell 10. In addition, by having the ability to control the distribution of the precipitates or reaction by-product during discharge, early passivation/deposition of the by-product on the fuel electrode 12 may be prevented. Passivation leads to lower fuel utilization and lower cycle life, which is undesirable.
The examples of
As noted, during a charging mode for the cell 10, a potential difference is applied across electrodes in the cell 10. Although either the oxidant electrode 14 or the separate charging electrode 70 generally function as the anode during charging, an anodic potential may be applied to other electrodes, such as some of the electrode bodies in the fuel electrode 12. Likewise, during charging a cathodic potential may be initially applied to electrode body 12a of the fuel electrode 12, but may also be initially applied to one or more of the other permeable electrode bodies 12b-12d of the fuel electrode 12. As such, those permeable electrode bodies 12a-12d of fuel electrode 12 having a cathodic potential behave as a cathode during charge, and serve as a reduction site for a reducible fuel species, such as the oxidized fuel ions created in the cell during discharging.
As the reducible fuel species is reduced on those of permeable electrode bodies 12a-12d having the cathodic potential, the oxidant electrode 14 or the separate charging electrode 70 and/or those of the permeable electrode bodies 12b-12d having the anodic potential will oxidize an oxidizable oxygen species, such as the reduced oxidant species created in the cell during discharging. Thus, when the cell 10 is a metal-air cell, the reducible metal fuel species is being reduced and electrodeposited on some of the permeable electrode bodies 12a-12d of the fuel electrode 12, and the oxidizable oxygen species is being oxidized to oxygen gas, which may be off-gassed from the cell 10. In this embodiment, those electrodes and electrode bodies having an anodic potential may be considered an oxygen evolving electrode (OEE).
To determine which of the electrodes (i.e. permeable electrode bodies 12a-d, the oxidant electrode 14 and/or the separate charging electrode 70) have anodic potentials or cathodic potentials during charging, electrical connections therebetween may be controlled by the switching system 60, as is discussed in greater detail below.
It may be advantageous to the fuel growth for the potential difference used to charge the cell 10 to be applied between adjacent bodies in the cell 10, such that an electrode body having the anodic potential is adjacent to an electrode body having the cathodic potential. Once sufficient fuel growth has occurred on the electrode body having the cathodic potential, the electrode having the anodic potential may change, so that the permeable electrode body that previously was part of a set of electrode bodies having an anodic potential may become part of a set of electrode bodies having the cathodic potential. In an embodiment wherein there are N permeable electrode bodies, the application of the anodic potential from the power source to permeable electrode bodies 2 to N and the charging electrode may comprise connecting all of the electrode bodies plus the charging electrode together at the same time, then disconnecting each of electrode bodies 2 to N in order. Alternatively, in an embodiment, the application of the anodic potential from the power source to permeable electrode bodies 2 to N and the charging electrode could comprise connecting and disconnecting each of the electrode bodies and the charging electrode individually in order (such that electrode body 2 is connecting to the anodic potential, then is disconnected and electrode 3 is connected to the anodic potential, and so on until the charging electrode is finally connected to complete the growth).
In an embodiment, the charging electrode may merely be the last electrode to receive the anodic potential during charging. For example, the charging electrode could be the oxidant electrode or a separate electrode. When the charging electrode is a separate electrode, it could have a specialized construction different from the electrode bodies of the fuel electrode, or could be the same as the permeable electrode bodies (i.e. just one more electrode body), but for the fact that growth of the fuel during charging does not continue past it.
In the above-described embodiment illustrated in
In
For example, a short between charging electrode 70 and the electrode bodies 12a-12d having a cathodic potential during charge (detected by voltage measurement as described below) may lead to expense of parasitic power during charge. An electrical short may lead to a sudden drop in voltage between the charging and fuel electrodes as the current is shunted between the charging and fuel electrodes. Another example is during discharge, where any cell 10 that has a higher kinetic or ohmic loss affects the round trip efficiency and discharge power of the stack. Also, consumption of fuel in the cell 10 during discharge earlier than other cells 10 can lead to voltage reversal in the cell 10 and stack power loss, and can be prevented by bypassing the cell 10 when the discharge voltage falls below a critical value. Complete consumption of zinc or other fuel during discharge leads to a sudden drop in voltage between the fuel and oxidant electrodes. Any other criteria to detect the performance of cells 10 may be used, and the examples herein are not limiting. Certain cells 10 may not meet performance requirements (for example, maximum power during discharge) due to yield issues and problems related to fabrication and assembly of electrodes. These cells 10 can be permanently placed in bypass mode. Other cells 10 may meet performance requirements initially, however may have cycle life issues and can be placed in bypass mode after the performance falls below a required limit. Thus, bypassing a cell 10 through bypass switch 150 provides an option to increase reliability and performance of the stack.
The switching system 60 of
A charging electrode switch 170 may be associated with the charging electrode 70, such that the charging electrode 70 may be electrically connected to the second terminal 140 when the power supply PS is connected between the first terminal 130 and the second terminal 140. As discussed below, the charging electrode 70 may not always have an anodic potential applied to it, and in an embodiment may only have an anodic potential when fuel growth between it and electrode body 12d is desired. Also shown are switches 180, 190, and 200, associated with electrode bodies 12b-12d respectively, all of which are configured to connect electrode bodies 12b-12d to the second terminal 140 as well.
As was noted, it is advantageous that an electrode having an anodic potential be adjacent to an electrode having a cathodic potential, so that growth on the electrode having the cathodic potential is enhanced. Such enhancement may, for example, include greater density of fuel growth than if the electrode having the anodic potential is further from the closest electrode having the cathodic potential (i.e. if a neutral electrode separates the electrodes having the anodic and cathodic potentials). This enhanced density may be due to the initial dendrites that first contact the anodic body being disrupted because they lack sufficient cross-section to carry the current between the anodic and cathodic bodies. That is, they burn off similarly to a fuse element subject to excess current. This delays shorting between the anodic and cathodic bodies, which takes place when the density has increased further to provide dendrites of sufficient cross-sectional area (individually and/or collectively) to enable the current conduction without disruption. Another advantage may be lower electrolyte IR loss in configurations where the distance between the charging electrode 70 and the fuel electrode 12 is lower, as compared to configurations wherein the electrode having the anodic potential is further from the closest electrode having the cathodic potential (i.e. where neutral electrodes separate the electrodes having the anodic and cathodic potentials). This IR efficiency advantage resulting from less distance between anodic and cathodic electrodes may be realized both in embodiments where metallic growth is occurring between the electrodes and in other embodiments, such as a metal hydride fuel where the hydrogen ions are being reduced.
To achieve progressive modification of which electrodes have the anodic potential, to account for shifts between electrodes having an anodic potential versus electrodes having a cathodic potential, the cell 10 in the charging mode would be configured such that the bypass switch 150 is open, so that current does not bypass the cell 10. Because the cell is in a charging mode, the oxidant electrode switch 160 is also open, so that the oxidant electrode 14 is electrically disconnected from the cell 10. Since initially fuel growth is desired on electrode body 12a, only electrode body 12a is electrically connected to first terminal 130, applying the cathodic potential thereto. To establish an anodic potential on the electrode body adjacent to electrode body 12a, at least electrode body 12b will be electrically connected to second terminal 140. To achieve this electrical connection in the illustrated embodiment, at least switch 180 is closed. In an embodiment, electrode bodies 12c-12d, and charging electrode 70 may also be electrically connected to second terminal 140, and thus may also have the anodic potential. Because of the potential difference between the electrode(s) having the anodic potential (i.e. initially electrode body 12a) and the electrode(s) having the cathodic potential (i.e. initially at least electrode body 12b), reducible fuel species in the ionically conductive medium may be reduced at the electrode having the initial cathodic potential (electrode body 12a) while cations in the ionically conductive medium are oxidized at electrode body 12b (and any other body/electrode to which the anodic potential is applied).
Once fuel growth on the electrodes having the cathodic potential progresses to a certain point, for example, to the point where an electrical connection is formed between the electrode(s) having the cathodic potential and the electrode(s) having the anodic potential, the switching system 60 may disconnect the shorting electrode body that had the anodic potential, such that that electrode body has a cathodic potential applied to it, and a potential difference may be formed again between adjacent electrode bodies. This may require the further electrical connection of the adjacent electrode body to the second terminal 140, if the electrical connection did not already exist, so as to create the anodic potential on that body. For example, in
The progressive shifting of which electrodes have the cathodic potential and which electrodes have the anodic potential may continue throughout the cell 10, with the opening of switches 190 and 200, until no further progression is desired or possible. For example, in the illustrated embodiment, wherein there is a separate charging electrode 70, the progression will end when the separate charging electrode 70 is the only electrode body having the anodic potential, and all permeable electrode bodies 12a-12d of the fuel electrode 12 have the cathodic potential. Charging of the cell 10 may subsequently end when fuel growth on electrode body 12d causes an electrical connection between electrode body 12d and charging electrode 70. In an embodiment, the switching system 70 may be configured to have an over-charge configuration, wherein the cell may be configured to selectively apply a cathodic potential to charging electrode 70 by opening switch 170, and closing switch 160, applying the anodic potential to the oxidant electrode 14, utilizing it for further charging of cell 10 by permitting fuel growth on the charging electrode 70.
Charging of the cell 10 may in various embodiments progress from electrode body to electrode body among the plurality of permeable electrode bodies 12a-12d, or may end based on criteria such as the voltage, current, slope of voltage, slope of current, charge capacity, or value of impedance or resistance. Such measurements in various embodiments may be taken over one or more of the electrode bodies 12a-12d, or across one or more cells 10. In an embodiment, charging may end based on a sensing electrode placed between the charging electrode and the last permeable electrode body 12d of the fuel electrode 12.
During discharge of the cell 10 in the embodiment of
Continuing to
During discharge of the cell 10 in the embodiment of
Another embodiment of the switching system 60 for the cell 10 is seen in
During discharge of the cell 10 in the embodiment of
The progressive shifting of which electrode bodies have a cathodic potential versus which electrode bodies have an anodic potential may be analogized as the cell 10 having N electrode bodies defining two conceptual electrodes, a cathodic potential electrode and an anodic potential electrode. In the cell, the constituent makeup of the cathodic potential electrode may begin with a single electrode body, while the anodic potential electrode may comprise at least the adjacent electrode body, up to all other electrode bodies. During charging, fuel grows on the cathodic potential electrode until, for example, no further growth on the electrode body is possible (i.e. the cathodic potential electrode has shorted to the anodic potential electrode). At that time, the electrode body of the anodic potential electrode that is adjacent to the cathodic potential electrode is reassigned to become part of the cathodic potential electrode, through an electrical connection formed by the fuel growth and/or through the use of electrical circuitry or switches associated with the electrode bodies of the cell. With the reassignment, the cathodic potential electrode now comprises two electrode bodies, while the anodic potential electrode has one less than its initial number of electrode bodies. As a potential difference may resume between the cathodic potential electrode and the anodic potential electrode, fuel growth from charging may resume, again until, for example, no further growth on the electrode bodies of the cathodic potential electrode is possible.
The progressive shifting of the constituent makeup of the cathodic potential electrode and the anodic potential electrode may continue throughout the cell, for example with the opening and/or closing of switches associated with the electrode bodies, until no further progression is desired or is possible. For example, once the anodic potential electrode comprises only a single electrode body, no further progression is possible. The charging of the cell may subsequently end when fuel growth on the cell causes an electrical connection to form between the conceptual cathodic potential electrode and the conceptual anodic potential electrode that comprises only a single electrode body.
Again, in various embodiments charging of the cell 10 may progress from electrode body to electrode body among the plurality of permeable electrode bodies 12a-12d, or may end based on criteria such as the voltage, current, slope of voltage, slope of current, charge capacity, or value of impedance or resistance. Such measurements in various embodiments may be taken over one or more of the electrode bodies 12a-12d, or across one or more cells 10. In an embodiment, charging may end based on a sensing electrode placed between the charging electrode and the last permeable electrode body 12d of the fuel electrode 12.
As noted previously, in an embodiment, multiple electrochemical cells 10 may be combined in cell system 100. Shown in
In any embodiment, the switches of the switching system 60 (or any other switch described herein) may be of any type, and the term switch is broadly intended to describe any device capable of switching between the modes or states described. For example, in some non-limiting embodiments, the switches may be single pole single throw or single pole double throw. They may be of the pivoting, sliding or latching relay type. Also, semiconductor based switches may be used as well. The switches may be activated electrically (electromechanical relay) or magnetically or by other methods known to those familiar in the art. Any other suitable type of switch may be used, and the examples herein are not limiting. In an embodiment, the plurality of switches may be connected in series if the switch has a leakage current in one direction. For example, the body diode of a MOSFET semiconductor based switch will conduct in one direction and the leakage current can be eliminated by placing MOSFET semiconductor based switches facing back to back in series.
Any suitable control mechanism may be provided to control the action of switches in the switching system 60 and/or the terminal selector system 62. As shown in
In an embodiment, the controller 230 may comprise hard-wired circuitry 232 that manipulates the switches based on an input 234 determining the proper switch configuration. The controller 230 may also include a microprocessor for executing more complex decisions, as an option. In some embodiments, the controller 230 may also function to manage connectivity between the load L and the power source and the first and Nth cells (i.e. may control the terminal selector system 62 described above). In some embodiments, the controller 230 may include appropriate logic or circuitry for actuating the appropriate bypass switches 150 in response to detecting a voltage reaching a predetermined threshold (such as drop below a predetermined threshold). In some embodiments, the controller 230 may further comprise or be associated with a sensing device 236, including but not limited to a voltmeter (digital or analog) or potentiometer or other voltage measuring device or devices, that can be used to determine when to modify the configuration of the plurality of switches, such as to maintain the proximity of the anode and the cathode as fuel growth progresses during charging. In some embodiments, the sensing device 236 may instead measure current, resistance, or any other electrical or physical property across or of the cell 10 that may be used to determine when to modify the configuration of the plurality of switches. For example, the sensing device 236 may measure a spike in current or a drop in potential difference between two electrode bodies. In some embodiments, the controller 230 may control the switches of the switching system 60 based on the passage of increments of time. For example, in an embodiment the time for fuel growth to progress between adjacent electrode bodies may be known, and used to calculate when to operate the switching system 60 so as to progressively rewire the electrodes to maintain an adjacent separation between the anode and the cathode. In an embodiment, the controller 230 may control the switches of switching system 60 to provide a high efficiency mode for the cell, such as is disclosed in U.S. Provisional Patent Application 61/323,384, now pending as U.S. patent application Ser. No. 13/083,929, each of which is incorporated in its entirety herein by reference.
In some embodiments, the controller 230 may be configured to selectively enter different charging modes. For example, in one mode a plurality of electrode bodies may initially have an anodic potential, but the number decreases as the electrode bodies are given a cathodic potential. In another mode, only a single electrode body has an anodic potential at any given time, and the electrode body with the anodic potential changes as prior electrode bodies are given the cathodic potential. For example, in the former mode, the controller 230 may close all switches associated with the charging electrode 70 and electrode bodies 12b-d during recharge, such that an anodic potential is applied to each of electrode bodies 12b-d and the charging electrode 70. The controller 230 may then progressively open the switches associated with each of electrode bodies 12b-d as the electrode bodies 12b-d progressively become electrically connected to electrode body 12a, and thus have a cathodic potential. In the latter mode, the controller may initially close only the switch associated with electrode body 12b, giving electrode body 12b an anodic potential while electrode body 12a has a cathodic potential. When fuel growth on electrode body 12a reaches electrode body 12b, creating an electrical connection therebetween, the controller 230 may open the switch associated with electrode body 12b that gave electrode body 12b the anodic potential, such that electrode body has a cathodic potential through its electrical connection to electrode body 12a. The controller 230 may then proceed to close the switch associated with electrode body 12c, to provide electrode body 12c with the anodic potential, again creating a potential difference, and the progression of fuel growth. These progressions of switch reassignments by the controller 230 may continue through or until only the charging electrode 70 has the anodic potential, as is described above.
As seen in
The method 240 starts at 250, and includes at 260 electrically connecting the cathode (i.e. in an embodiment, initially just permeable electrode body 12a), distal from the charging electrode, to the negative terminal of power supply PS, and the anode (i.e. initially at least permeable electrode body 12b) to the positive terminal of the power supply PS, creating a potential difference therebetween. The method 240 continues at 270, wherein, the fuel is electrodeposited on the cathode (i.e. at least permeable electrode body 12a). As seen in step 280, the method 240 may continue by determining if fuel growth has progressed to beyond a threshold amount. In an embodiment the threshold amount may be ascertained when the cell 10 is shorted by the fuel growth creating an electrical connection through the fuel growth between the cathode (i.e. permeable electrode body 12a) and the anode (i.e. permeable electrode body 12b). As shown, if fuel growth has not reached the threshold amount, the growth of fuel at 270 is repeated. Once the threshold amount is reached, the method continues at 290, wherein it may be determined if further fuel growth is both possible and desired. In an embodiment, the determination at 290 may include ascertaining if there are additional electrode bodies, such as permeable electrode bodies 12c-d, that fuel growth may be possible on. If so, the method continues at 300 by using the plurality of switches of the switching system 60 to disconnect the connecting electrode body (i.e. permeable electrode body 12b) from the anode, and if it were not connected through the switching system 60 before, connecting the next adjacent electrode body (i.e. permeable electrode body 12c) to the anode. This creates the potential difference between the cathode (now comprising permeable electrode bodies 12a-b) and the anode (comprising at least permeable electrode body 12c). The method 240 then returns to 270 wherein fuel growth continues on the cathode. If no further fuel growth is possible or desired at 290, the method 240 continues to 310 by disconnecting at least the negative terminal of the power source PS from the cell 10 to discontinue the charging process. The method 240 may then end at 320.
Shown in
The method 330 starts at 340, and includes at 350 using the plurality of switches of the switching system 60 to connect the permeable electrode bodies 12a-d that contain fuel. In an embodiment, if the cell 10 is completely charged all permeable electrode bodies 12a-d would be electrically connected to one another. As the cell 10 is in discharge mode, the plurality of switches of the switching system 60 would be configured to electrically disconnect the separate charging electrode 70 (if present). In an embodiment, the method 330 would continue at 360 by electrically connecting the cathode (i.e. the air cathode, oxidant electrode 14) to the negative terminal of load L, and the anode (i.e. the fuel electrode 12, containing the electrically connected permeable electrode bodies 12a-d) to the positive terminal of the power supply PS, creating a potential difference therebetween. The method 330 continues at 370, wherein the fuel is consumed on the fuel electrode 12. In an embodiment, because the plurality of switches 60 connect the permeable electrode bodies 12a-d, an anodic potential is applied to each of the permeable electrode bodies 12a-d, and fuel may be consumed from each or any of permeable electrode bodies 12a-d. As seen in step 380, the method 330 may continue by determining if consumable fuel has been depleted from any permeable electrode body 12a-d. In an embodiment, a sensor, such as the sensing device 236 above, which may include a current or a voltage sensor, may be present in the cell 10, and may indicate when consumable fuel has been depleted from one or more of the permeable electrode bodies 12a-d. If no depletion is detected, the discharging may continue as method 330 returns to step 370. If, however, consumable fuel has been depleted from one or more of permeable electrode bodies 12a-d, then method 330 may continue to step 390, wherein it may be determined whether there are any remaining permeable electrode bodies 12a-d that contain consumable fuel. This determination may be made simultaneously with the determination of depletion in step 380, and may be made through a survey of sensing device(s) 236, or by any other appropriate method.
If consumable fuel remains on one or more of permeable electrode bodies 12a-d, the method 330 may continue at step 400, wherein the switching system 60 adjusts the plurality of switches so that any of permeable electrode bodies 12a-d that lack consumable fuel are disconnected from fuel electrode 12. In an embodiment, consumption of fuel may initially be from the electrode body that is closest to the oxidant electrode 14 (such as, for example, permeable electrode body 12d in the illustrated embodiments above), and switching system 60 may disconnect permeable electrode body 12d, 12c, and 12b in that order, until all fuel is consumed from permeable electrode body 12a. Once none of the permeable electrode bodies 12a-d contain consumable fuel, or further discharging is no longer desired (or possible), the method may continue to step 410, wherein the load L may be disconnected. In an embodiment, the load L may remain connected to the cell 10 when it is depleted, until the cell 10 is recharged, in which case it may be disconnected so that the cell 10 may be connected instead to the power supply PS. The method 330 may then end at 420.
As in the above embodiments, the cell 10 may have the bypass switch 150 configured to connect first terminal 130 directly to second terminal 140, bypassing the cell 10 in cases such as where a fault is present within the cell 10, or for any other reason where utilization of the cell 10 is not desired. The oxidant electrode 14 is again selectively connected to the second terminal 140 for discharging by oxidant electrode switch 160, and the separate charging electrode 70 is again selectively connected to the second terminal 140 for charging by the charging electrode switch 170. In the illustrated embodiment, the electrode bodies 12b-e may be selectively connected to either the first terminal 130 or the second terminal 140 by electrode body switches 425b-e, where “b” through “e” indicate which of electrode bodies 12b-e are associated with the respective switch. As is shown in the illustrated embodiment, electrode body switches 425b-e are configured to alternatively connect each of electrode bodies 12b-e to either a first bus 427a associated with electrode body 12a (and thus first terminal 130), or a second bus 427b associated with the separate charging electrode 70 (and thus second terminal 140 through charging electrode switch 170). In an embodiment, electrode body switches 425b-e may be characterized as Single Pole, Double Throw. In some embodiments, electrode body switches 425b-e may have three alternative settings, such that each electrode body 12b-e may be electrically connected to electrode body 12a (and first terminal 130), separate charging electrode 70, or disconnected from both electrode body 12a and separate charging electrode 70. In an embodiment, such electrode body switches 425b-e may be characterized as Single Pole, Triple Throw.
During charging of the electrochemical cell 10, power is applied from a power supply between first terminal 130 and second terminal 140. Bypass switch 150 would be open so that there is no short between first terminal 130 and second terminal 140. Since the cell 10 is in a charging mode, the oxidant electrode 14 is not utilized, so oxidant electrode switch 160 is also open. Accordingly, during charging the charging electrode switch 170 would be closed. As each of electrode bodies 12b-e may be selectively coupled to the anode or the cathode in this embodiment, charging techniques such as but not limited to the progressive OEE described above, or that disclosed in U.S. Provisional Patent Application No. 61/383,510 and U.S. patent application Ser. No. 13/230,549, each of which is incorporated herein in its entirety by reference, may be utilized. The operation of electrode body switches 425b-e in some embodiments is discussed in greater detail below.
Turning now to the flowchart in
In an embodiment the algorithm 430 may include instructions, such as computer interpretable or readable instructions, that may program or otherwise control the controller 230. In some embodiments, the algorithm 430 may be located on a system that is networked with or otherwise connected to controller 230. In some embodiments, the algorithm 430 may be stored on a medium within controller 230, or within any other controller that may allow programmatic control of the switches in switching system 60.
As shown, algorithm 430 may be configured, at 440, to select a particular charge mode for the cell 10. The selection of the charge mode may be made by any appropriate determination criteria 450. For example, in an embodiment the determination criteria 450 may include measurements 460 of the cell 10. The measurements 460 of the cell 10 may be any appropriate measure of the status of the cell, including but not limited to sensor readings pertaining to the current status of fuel growth on permeable electrode bodies 12a-e, readings of the current electrical connections formed by the switching system 60, measurements of a voltage and/or current from or through the cell 10, or so on. To ascertain measurements 460, controller 230 may utilize sensing device 236, which in the current embodiment shows leads extending across the cell 10, between first terminal 130 and second terminal 140.
Measurements 460 may also include measures of the environment. In one embodiment, measurements 460 of the environment may include ascertaining the current time. For example, where the cell 10 is associated with a solar power system, charging earlier in the day may utilize a different charge mode than charging when the sun is closer to setting. Other measurements 460 of the environment are also possible. For example, in some non-limiting embodiments, measurements 460 may be of the environmental temperature, weather conditions, ambient light, movement of the cell 10 (i.e. if the cell 10 is utilized in a vehicle, different charge modes may be utilized for different speeds or braking styles), or so on.
Determination criteria 450 may also include manual overrides 470, which may include any form of manual selection as to which charge mode is desired. Such a manual selection for manual overrides 470 may, in an embodiment, be provided to the controller 230 by input 234. In an embodiment, determination criteria 450 may also include limits 480, which for example may determine an appropriate charge mode based on exceeding predefined tolerances or settings. For example, limits 480 may be based on the measurements 460, and include, for example, voltage difference between electrodes or electrode bodies, current impedance between electrodes or electrode bodies, or so on. In various embodiments, limits 480 may be based on voltage, current, slope of voltage, slope of current, charge capacity, or value of impedance or resistance, for example. Such limits 480 may be based on measurements 460 on or across one or more electrode bodies 12a-e, or on or across one or more cells 10.
Once the charge mode is selected at 440, the controller 230 may identify the charge mode at 490, and proceed to charge the cell 10 accordingly. Although in an embodiment the charge mode may be one which utilizes a progressive OEE, such as that described above, in the illustrated embodiment the controller 230 is configured to select from two alternative charge modes, a progressive charge mode 500, and a parallel charge mode 600. In other embodiments, additional or alternative charge modes may be utilized, and may be in accordance with the algorithm 430.
As shown in the illustrated embodiment, progressive charge mode 500 is a high capacity charge mode. This implies that the cell 10 is configured to be charged in a manner that provides a significant amount of density in the fuel growth between electrode bodies 12a-e. In some embodiments, this high capacity charge mode may take a longer interval of time to complete the charging process, but may enable the greatest amount of energy storage within the cell 10. Such a charging mode may be useful for a number of applications, including but not limited to emergency backup power and uninterruptible power supplies, where a larger amount of power may be needed, and a relatively large amount of time is available to recharge the cell 10 following its use. In such applications the amount of energy stored in cells 10 is of greater importance than the charging rate. Because the charging process is roughly serial between the electrode bodies of the fuel electrode 12, the charging rate is slower than in other embodiments. In the illustrated embodiment, wherein the cell 10 has five electrode bodies 12a-e in the fuel electrode 12, and a separate charging electrode 70 (i.e. the dedicated oxygen evolving electrode, or OEE), the progressive charging mode 500 may include five phases.
When the cell 10 is uncharged, the progressive charge mode 500 may begin at a first phase 505, wherein only the first electrode body 12a forms the cathode, while electrode bodies 12b-e and the separate charging electrode 70 form the charging electrodes. In the embodiment of
Once the fuel growth reaches a sufficient amount that electrode body 12a and electrode body 12b short together at 510, the progressive charge mode 500 would proceed to a second phase at 515, wherein electrode bodies 12a-b form the cathode, while electrode bodies 12c-e and the separate charging electrode 70 form the charging electrodes. In the embodiment of
As fuel growth progresses through the cell 10, the progressive charge mode 500 may electrically disconnect the contacting electrode body 12b-e from the second bus 427b, and connect it instead to the first bus 427a, progressively reassigning it form a charging electrode to a cathode. In embodiments wherein electrode body switches 425b-e are Single Pole, Triple Throw, the electrode body switches 425b-e may either be configured to connect contacting electrode bodies 12b-e along first bus 427a, or the electrode body switches 425b-e may move to their electrically disconnected position, such that their electrical connection to first terminal 130 is through the fuel growth alone. As depicted in the flowchart of
Once all electrode bodies 12b-e are connected with electrode body 12a, by the fuel growth through electrode bodies 12a-e and/or electrical connections through the first bus 427a, the fuel may continue to grow on electrode body 12e towards the separate charging electrode 70, due to the potential difference between those electrodes. Eventually, at 550, it may either be determined that electrode body 12e has shorted with the separate charging electrode 70, indicating maximum fuel growth throughout the cell 10, or a threshold charge capacity has been reached. Such a threshold capacity may be defined so that the cell does not “over-charge.” For example, in some embodiments it may be undesirable that fuel growth reach and form an electrical connection to the separate charging electrode 70. In an embodiment, the threshold charge capacity may be approximately 80-100% of the maximum possible charge capacity for the cell 10. The measurement of capacity may be made by any suitable mechanism, including in some embodiments taking measurements with the sensing device 236, or computing or estimating a charge capacity through controller 230. Regardless, once the threshold capacity has been reached, or electrode body 12e has shorted with the separate charging electrode 70, the cell may enter an idle state, to await a future discharge mode.
If during the selection of the charge mode at 440, a desire for a faster charge is indicated, the parallel charge mode 600 may be selected at 490. In the parallel charge mode 600, mini-cells may be formed within the cell 10, with alternating bodies between electrode body 12a and the separate charging electrode 70 acting as either an anode or a cathode. In an embodiment, the parallel charge mode 600 may be N times faster than progressive charge mode 500 (where N is the number of electrode bodies that metal fuel is being plated on). In an embodiment, the growth rate on a given electrode body is limited by the diffusion-limited current density of the metal fuel deposition, which is affected by a number of factors, including viscosity, concentration, diffusity, and so on. Although the parallel charge mode 600 would be faster than the progressive charge mode 500, the fuel growth may be potentially less dense than in the progressive charge mode 500, because the total charge deposited is limited by the time taken for electrical connections to form between all electrode bodies. In some embodiments, the energy density held by the cell 10 charged by the parallel charge mode 600 may be ¼ to ½ that of the cell 10 charged by the progressive charge mode 500. Some examples of applications that would prefer the parallel charge mode 600 may include, for example, electric vehicles such as forklifts or cars, where a faster charge rate may be of greater importance than a larger charge density, like when the vehicle is being continuously used in close proximity to charging opportunities.
In an embodiment, the parallel charge mode 600 may begin at a first phase 605, with electrode bodies 12a, 12c, and 12e connected to the first terminal 130, while electrode bodies 12b and 12d, as well as the separate charging electrode 70, are connected to the second terminal 140. In the embodiment of
As charging progresses during the first phase 605 of the parallel charge mode 600, fuel growth may be bi-directional on the intermediate electrode bodies 12c and 12e that are acting as cathodes. In the embodiment of
If any of the continuity tests at 610 indicate an electrical connection has formed between an anode and a cathode, the parallel charge mode 600 may progress to an iterative next phase at 615, wherein any shorted charging electrode (i.e. electrode body 12b or electrode body 12d) is electrically disconnected from the second terminal 140. For example, if any short occurs between the first bus 427a and the second bus 427b, whichever of the switches 425b-e that can be thrown to eliminate that electrical connection may be thrown accordingly.
In an embodiment, any of the intermediate electrode bodies 12b-e may be reassigned from acting as anodes to acting as cathodes, or vice versa, based on the electrical connections formed during the parallel charge mode 600. For example, if fuel growth electrically connects electrode body 12c (as a cathode) to electrode body 12d (as a charging electrode), while electrode body 12e is still growing fuel, the controller 230 may assign the pair of fuel-linked electrode bodies 12c-d to act together as a charging electrode, in that both electrode body switches 425c-d connect electrode bodies 12c-d to second terminal 140 via second bus 427b, so that bidirectional fuel growth of fuel on electrode body 12e continues. If fuel growth on electrode body 12a has electrically connected electrode bodies 12a-b, then electrode body 12b would be electrically disconnected from second bus 427b, such that a potential difference exists between electrode bodies 12a-b and electrode bodies 12c-d, so that additional fuel growth can occur on electrode bodies 12a-b (as a cathode) towards electrode bodies 12c-d (as a charging electrode).
If fuel growth on electrode body 12e, which is initially a cathode electrically connected to first terminal 130 via electrode body switch 425e and first bus 427a, causes a short with separate charging electrode 70, controller 230 may then throw electrode body switch 425e to electrically disconnect electrode body 425e from first bus 427a, such that electrode body 12e and the separate charging electrode 70, as well as the metal fuel therebetween, all act as an interconnected charging electrode. If electrode body 12d is then reassigned as a cathode (due to electrical connection with electrode body 12c, for example), then fuel growth may continue from electrode body 12d toward electrode body 12e, due to the potential difference therebetween.
In such a manner, the reassignment of electrode bodies 12b-d may progress, measured by the continuity tests at 610, until, at 620, either all electrode bodies 12a-e and the separate charging electrode 70 have shorted, or a threshold capacity for the cell 10 has been reached. Again, the reaching of the threshold capacity may be ascertained by any suitable mechanism, including in some embodiments taking measurements with the sensing device 236, or computing or estimating a charge capacity through controller 230. Regardless, once the threshold capacity has been reached, or all electrodes in the cell 10 have shorted, the cell may end the parallel charge mode 600 and enter an idle state, to await a future discharge mode.
In some embodiments, the controller 230 may be configured to charge the cell 10 such that some of the electrode bodies 12a-e are charging in accordance with progressive charge mode 500, while others of electrode bodies 12a-e are charging in accordance with parallel charge mode 600. In some embodiments, the varying desires of charge rate and energy density may be implemented in the charge mode selection at 440 throughout the charging of the cell 10, such that the real time needs of the application utilizing the cell 10 may be taken into account. In an embodiment the controller 230 may measure typical discharge characteristics of the cell 10 over time, and modify the selection of the charge mode at 440 accordingly. As one non-limiting example, if the cell 10 is utilized in an electric vehicle that is utilized intermittently during daylight hours, but is not utilized at night, then the controller 230 may utilize the parallel charge mode 600 to quickly charge the vehicle as needed during the daylight, however may utilize the progressive charge mode at night, so that the greater amount of stored energy is held by the cell 10 for use the following day. In an embodiment, the controller 230 may be more sophisticated, and may compute a more complex optimal energy vs. charge rate, to provide the optimal quantity of run time based on the usage of the cell 10.
It may be appreciated that in some embodiments the controller 230 may also be configured to discharge the cell 10 in a variety of modes. In some embodiments, the algorithm 430 may be further configured to select between a charging mode and a discharging mode. In other embodiments, a separate discharging algorithm may be provided for the discharge mode or modes. In some embodiments, differing modes of charging and discharging the cell 10 may be managed by a broader “cell operations” algorithm, which may be run on controller 230, for example. In some embodiments, only the oxidant electrode 14 and a distal electrode body (i.e. permeable electrode body 12a) are electrically connected to the load L, such that only the fuel electrically connects the permeable electrode bodies 12a-e. During discharge, the fuel would progressively be consumed from electrode body 12e (proximal to the oxidant electrode 14), towards the distal electrode body 12a. Once fuel is sufficiently consumed from each of the intermediate permeable electrode bodies 12b-d, those bodies would electrically disconnect from the fuel electrode 12 connected to the load L.
In some embodiments, the switching system 60 may be used to selectively connect the permeable electrode bodies 12b-e to the load L. In an embodiment, permeable electrode bodies 12b-e may all be connected to the load L throughout the discharging of the cell 10. In other embodiments, control of which electrode bodies (i.e. permeable electrode bodies 12b-e) are electrically connected to the load L may be ascertained by the discharging algorithm, and may depend on a particular discharge mode. In an embodiment, the determination to selectively connect or disconnect the permeable electrode bodies 12b-e from the load L may be based on measurements, manual overrides, or limits, which may be similar to those of determination criteria 450 that are used to determine the charge mode at 440 described above. For example, the decision to connect or disconnect one of the permeable electrode bodies may be based on criteria such as the voltage, current, slope of voltage, slope of current, charge capacity, or value of impedance or resistance. Such measurements in various embodiments may be taken over one or more of the electrode bodies 12a-12e, or across one or more cells 10. In an embodiment, sensors such as sensing device 236 associated with one or more of the electrode bodies 12a-e and/or one or more of the cells 10 may be utilized to take the measurements.
As above, in an embodiment the sensing device 236 may be, for example, a voltmeter (digital or analog), potentiometer, or other voltage measuring device or devices, which can be used to determine when to modify the configuration of the plurality of switches. In some embodiments, the sensing device 236 may instead measure current, resistance, or any other electrical or physical property across or of the cell 10 that may be used to determine when to modify the configuration of the plurality of switches. In some embodiments, the controller 230 may control the switches of the switching system 60 based on the passage of increments of time. For example, in an embodiment the time for fuel consumption between adjacent electrode bodies may be known, and used to calculate when to operate the switching system 60 so as to disconnect depleted ones of the electrode bodies 12b-e.
The foregoing illustrated embodiments have been provided solely to illustrate the structural and functional principles of the present invention, and should not be regarded as limiting. To the contrary, the present invention is intended to encompass all modification, substitutions, and alterations within the spirit and scope of the following claims.
The subject matter claimed in the present application, owned by Fluidic, Inc., was developed as a result of activities undertaken within the scope of a license agreement qualifying as a joint research agreement under 35 U.S.C. §103(c)(2) and (3) between Fluidic, Inc. and Arizona Science and Technology Enterprises, LLC acting for the Board of Regents for and on behalf of Arizona State University, which was in effect prior to development of the claimed invention.
The present application claims priority to U.S. Provisional Application Ser. No. 61/414,579 filed on Nov. 17, 2010, the entirety of which is incorporated herein by reference.
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