Patent Application
20130216921
With the ubiquity of consumer electronics, as well as many other products powered by stored energy, and the attachment to such products that users have, a need exists to provide the user with the ability to power directly or recharge electronic devices while traveling, and often quickly. Numerous formats exist for attempting to address this problem, whether it is the user traveling with an ample supply of double-A and triple-A batteries, or their having purchased a back-up battery where product-specific batteries are required for the product, or whether it requires the user to purchase and transport more elaborate recharging systems, including fuel cells or other means of harnessing electrochemical and even thermal energy.
Yet competing issues remain, economic viability and appeal versus the production and disposal of such recharging formats. It has been established that certain catalysts enhance the efficiency and durability of electrochemical energy for batteries and fuel cells. For example, the use of catalytic nano-metals produced by a process described in U.S. Pat. No. 7,282,167 to Douglas Carpenter of QuantumSphere, Inc. of Santa Ana, Calif., and described for numerous commercial applications in other patents and patent applications assigned to QuantumSphere, has proven very effective in high efficiency power storage and delivery. In that regard, reference is made to electrodes made using such catalytic nano-metals, including those expressly described in U.S. patent application Ser. No. 11/254,629, filed Oct. 20, 2005, (published as No. 2007-0092784), the entire contents of which are incorporated herein expressly by reference.
Yet, even then, consumer needs and desires, both sensible and fickle, are dynamic. Form factor is a very important design parameter, as it impacts not only convenience and portability, but also visual appeal. Light, powerful, sleek, and low-profile, are just some of the metrics by which consumers select electronic products. Coupled with a growing desire to empower our society with energy that has minimal ecological impact, there is a need to provide updated recharging technology that is efficient, effective, appealing, portable, virtually non-toxic and can be disposed of in an acceptable manner. Indeed, several entities are engaged in research to address these competing needs, with some having already launched commercially. Yet, there is still room for improvements. There is a strong trend toward rechargeability-reusability, even of the recharging source itself (e.g., rechargeable batteries, fuel cells that can be recharged, etc.). While beneficial in some respects, disposability, also has advantages.
For example, primary metal-air batteries, including zinc-air batteries, are not electrically rechargeable and must be disposed after use, but offer an effective power source given its low cost and high energy density. Typical zinc-air batteries have a button form factor, and comprise an anode of zinc and electrolyte, a cathode positioned discretely from the anode by a separator and insulator gasket, and a current collector. The cell includes a housing enclosing the electrodes, with an inlet through the wall on the cathode side for air exposure to the cathode through a semi-permeable membrane. Normally, zinc is mixed into a paste with an electrolyte to form a porous anode. Oxygen from the air reacts at the cathode and forms hydroxyl ions that migrate into the zinc paste and form zincate (Zn(OH)4), releasing electrons that can travel to the cathode. Eventually, the zincate decays into zinc oxide, with the water and hydroxyls from the anode being reused at the cathode. The known chemical reactions that take place in a zinc-air battery are as follows:
Anode: Zn+4OH−→Zn(OH)42−+2e− (E0=−1.25 V)
Fluid: Zn(OH)42−→ZnO+H2O+2OH−
Cathode: ½O2+H2O+2e−→2OH− (E0=0.34 V pH=11)
Overall: 2Zn+O2→2ZnO (E0=1.59 V)
Although zinc-air batteries are theoretically capable of producing almost 1.6 volts, due to practical inefficiencies, a normal zinc-air battery provides about 1.4 volts of energy.
Embodiments of the inventions described below address at least some of the needs discussed above, and take advantage of the advantages of high energy densities, abundant low cost materials, and eco-friendly disposability.
In one embodiment of the present invention, a system is provided for delivering energy to an electronic device, where the system comprises a metal-air battery having one or more zinc-air cells within a housing. The housing preferably includes at least one opening for permitting the influx of air from the surrounding ambient into the interior of the battery housing for exposure to the one or more cells. A plurality of air holes, in one or more of a variety of configurations and shapes are contemplated.
The battery system further comprises a cover that may be entirely or partially moved relative to the opening for selectively controlling the exposure of ambient air when it is desired to generate energy for discharge to the rechargeable power source. The cover may be moved by sliding, rotating, pivoting, peeling, collapsing, or one of many other formats, depending upon the construction and configuration of the cover and/or the housing in which the cells are positioned. The cover may be removable or not, with removable covers being reusable or disposable.
The battery further comprises a connector for permitting electrical connection between the system and the electronic device. In one embodiment, the connector may be a lead wire terminating with a connector, or the connector may be an electrical port. In another embodiment, a transformer may be used to change the voltage.
The system may further comprise a carriage for supporting the battery in a manner where the battery may be easily removed and/or repositioned. Preferably, electrical contacts are provided both on the battery and on the carriage so electrical communication may occur between the two when the battery is positioned within the carriage. In an alternative embodiment, no cover is provided on the battery, and exposure of the air hole(s) is controlled by orienting the battery within the carriage in a certain position or orientation. Where the battery has one face with one or more air holes, and an opposite face with no air holes, flipping the battery within the carriage can alternatively expose the air holes or seal off the air holes.
Embodiments of the invention herein may be used to recharge batteries employed in an electronic device, or simply to power the device directly. Such devices may include one of number of consumer electronic devices, including computer-based devices or less complex devices such as flashlights, as well as larger devices such as those used in commercial and industrial applications, or even in vehicles. Other possible applications are contemplated as well for the battery systems described herein.
Referring to
As a vehicle for permitting the influx of air, the second face 18 of housing 12 comprises one or more openings 18 for permitting an exchange of air within the interior of the housing 12, as shown specifically in
The zinc-air battery 10 embodiment of
Referring to
Referring to
The anode 26 preferably comprises an active metal, an electrolyte, deionized water and a binding gel. In one embodiment, the active metal comprises zinc particles. The electrolyte may comprise, for example, potassium hydroxide (KOH), with the binding gel comprising, for example, a Lubrizol® brand gelling agent such as Carbopol® EZ-3. The zinc, KOH electrolyte, binding gel and water are mixed to create a porous paste that resides preferably on a robust conductive mesh substrate such as nickel. Other materials may be used for the anode 26 in addition to or in substitution of the zinc, (KOH), water and binding gel, although the energy potential may differ, and the rate of discharge and storage life may also differ.
The cathode 28 preferably comprises nano-catalyst and carbon powder mixed with, for example, a fluorocarbon material, such as liquid Teflon® material, to form a ribbon-like substance applied to a nickel screen that serves as the current collector. These ingredients are applied to a porous Teflon® hydrophobic membrane to form the cathode 28. The nano-catalyst preferably comprises manganese or manganese alloy preferably made by, for example, a process described in the '167 patent to Carpenter referred to above. Preferably, the nano-catalyst comprises an external layer of oxide of the metal with a metal core to enhance stability and performance of the catalyst. The porous Teflon layer lets oxygen enter through the cathode 28 but restricts the exchange water into or out of the cell.
As with the anode, other materials may be chosen in addition to or in lieu of these materials if so desired. Other catalytic nano-metals may be used for the metal-air battery electrodes, including, for example, nickel, cobalt, silver, alloys thereof, and their respective oxides. Chromium, ruthenium, palladium, lead, iron, gold, and their associated alloys and oxides, among other metals, are also useful in some embodiments. Moreover, the possible variations on the composition of the cathode are described in more detail in U.S. patent application Ser. No. 11/254,629, filed Oct. 20, 2005, (published as No. 2007-0092784), the entire contents of which are incorporated herein expressly by reference.
In making the cell 24, the anode 26 and cathode 28 are adhesively joined to either side of the separator 30, which is formed of for example Celgard 5550-1270M-A, although other materials would be suitable. The separator membrane permits controlled exchange of reactants between the anode and cathode with minimum impeding of the zinc-air reaction that generates current at a desired voltage. In that regard, lead wires 34a and 34b extend from both electrodes to deliver energy at point 38 so that a plurality of cells 24 may be wired in parallel or series depending upon the energy output desired. It should also be noted, however, that depending upon the current and voltage level desired, a single metal-air cell may be sufficient within the battery housing. In either case, as exemplified by the embodiment of
Referring now to
In an alternative embodiment, and referring to
The advantage of providing a metal-air battery comprising a housing with air holes provided in at least one wall of the housing, and a cover to controllable expose air holes to ambient air, is that the system may function for long term storage by the user with the ability to start and stop the energy generating reaction as needed. Such an arrangement and configuration provides optimal benefit to a user with one or more rechargeable electronic devices who does not desire to maintain a supply of “back-up” batteries for each of the electronic devices. Disposability also provides an advantage of eliminating the need to recharge both an external rechargeable battery and the electronic device battery. It should also be noted that the battery may comprise one of a variety of shapes and configurations while still providing the beneficial advantages discussed above. The invention is not limited to a rectilinear housing profile, and may comprise curvilinear profiles if so desired.
It is contemplated that the lead wire 20 of the embodiments of
It is also contemplated that the air holes may be of any shape and configuration. Indeed, there may be one large one, or a plurality of smaller ones as described herein. The holes may be round, ovate, rectilinear, curvilinear or of any other shape that reflects functional and/or aesthetic appeal, including slots and cross-shapes.
Referring to
The carriage 114 comprises, in this example, a frame-like configuration comprising a first face 124 and a second opposing face 126, and an interior space 128 configured and sized to accommodate a removably secured position of the metal-air battery 112. In the embodiment illustrated, the first face 124 may be visible through the space 128, although it need not be. Where the space 128 is configured to closely conform to the profile of the battery 112, an optional notch 130 may be provided to facilitate removal of the battery when lodged within the space.
In one respect, the embodiment of
Preferably, a seal is provided either on the battery 112, or within the space 128, or both, so that when the battery is oriented with the air holes 120 facing inwardly, the seal precludes the flow of ambient air into the air holes. In the embodiment illustrated in
One advantage of the configuration of the embodiments such as that shown in
It is contemplated that, in some embodiments, the carriage may be adhered to one surface of the user's electronic device so that it is transported with the device and, thereby, easily accessible as recharging of the device's battery is required. In that regard, the first face 124 of the carriage 114 may be provided with an adhesive material that is reusable; i.e., that it may be sufficiently strong to adhere to an adjacent surface of a separate electronic device, but may be removed easily without losing its adhesive ability. Once the battery (for example battery 112) is fully discharged, a new battery may be placed inside the carriage or, if so desired, the entire battery and carriage disposed and replaced with a new set of battery and carriage.
Although not shown, the system 110 of
Referring to
Preferably the cover 240 comprises a plurality of openings that reflect indicia of operation mode, where the openings generate a first visual impression in one mode of operation and a second visual impression in a second mode of operation (i.e., inactive versus discharge modes). In one embodiment, shown in
It is important to recognize that a battery with a cover provided to control ambient air accessing the interior of the battery may be used with a carriage or self-standing. Where a cover is provided, the battery may reside in the carriage merely for convenience of transport, but it need not be removed and flipped over to activate the battery. Removal (partial or whole) or movement of the cover to expose the air holes in the battery would be sufficient to activate the battery. Once fully discharged, the battery may be removed from the carriage for disposal and replaced with a new battery of the type described herein.
Referring to
Of course, it may be appreciated that the possible physical arrangement for a plurality of such joined cell sets is inumerable, but one example 410 is shown in
In one particular battery system 510, shown in
It is contemplated that the housing 512 have a sealable lid or cover (not shown) to preclude exposure of the battery cells 312 to ambient air during remote transport of the portable power system 510. When power is desired, the cover or lid may be opened or pulled back (depending upon the particular configuration) to expose the battery 340 to air permitting the battery cells to generate power. If desired, the lid may be fashioned to sealably expose the outlets of the transformer for quick recharge of or power for an external device using residual air within the housing 512 with minimal exposure of the battery 340 to the air (preserving power for later discharge).
It is important to note that a plurality of battery systems 510 may be electrically linked in series and/or parallel to increase voltage and/or amperage. Such flexibility is important where higher power output is necessary in the context of larger industrial, medical and/or military equipment off the grid or in a back-up mode of operation.
It should be appreciated that numerous variations on the shape and configuration of the battery and/or the carriage are contemplated that reflect functional and aesthetic appeal to consumers. Moreover, aesthetics may take a back seat to functionality where the present invention is adapted for industrial use or in large scale formats. Indeed, it is contemplated that a large-scale format of the present invention may be provided for recharging batteries such as those used in electric and/or hybrid vehicles. The scope of the invention, therefore, should be defined by the claims as set forth below rather than by the examples expressly illustrated, described or suggested.
