Metal-air battery container

Details Metal-air battery container Metal-air battery container

1999-08-13

2001-05-15

Maples, John S. (Department: 1745)

Chemistry: electrical current producing apparatus, product, and

With pressure equalizing means for liquid immersion operation

C429S006000, C429S006000, C029S623100

Reexamination Certificate

active

06232007

ABSTRACT:

BACKGROUND OF THE INVENTION
The invention generally relates to a container for a metal-air battery.
Batteries are commonly used electrical energy sources. A battery contains a negative electrode, typically called the anode, and a positive electrode, typically called the cathode. The anode contains an active material that can be oxidized; the cathode contains or consumes an active material that can be reduced. The anode active material is capable of reducing the cathode active material. In order to prevent direct reaction of the anode material and the cathode material, the anode and the cathode are electrically isolated from each other by a separator.
When a battery is used as an electrical energy source in a device, such as a cellular telephone, electrical contact is made to the anode and the cathode, allowing electrons to flow through the device and permitting the respective oxidation and reduction reactions to occur to provide electrical power. An electrolyte in contact with the anode and the cathode contains ions that flow through the separator between the electrodes to maintain charge balance throughout the battery during discharge.
In a metal-air electrochemical cell, oxygen is reduced at the cathode, and a metal is oxidized at the anode. Oxygen is supplied to the cathode from the atmospheric air external to the cell through one or more air access port(s) in the cell container.
During high rate discharge conditions, the flow of air across the cathode is not always uniform. Instead, the areas of the cathode closest to the air access ports can be over-utilized, while the areas of the cathode that are farther away from the air access ports can be under-utilized. Uneven use of the cathode can lead to poor battery performance and reduced battery life.
SUMMARY OF THE INVENTION
The battery of the invention has one or more louvers that allow air to flow from the atmosphere to the cathode surface of the battery. The louvers help to distribute the air evenly to all parts of the cathode surface.
In one aspect, the invention features a metal-air battery having (a) an anode; (b) a cathode; (c) a separator between the anode and the cathode; and (d) a container having one or more louvers.
The louvers provide air flow to large portions of the cathode surface, while maintaining the structural integrity of the battery container. A battery container with louvers can be combined with a variable-thickness membrane. The portions of the membrane closer to the louver openings are thicker than the portions of the membrane farther away from the louver openings. This configuration provides for air diffusion paths of relatively uniform lengths to all portions of the cathode.
In another aspect, the invention features a process for making a metal-air battery. The process includes (a) providing one or more louver(s) in a battery container; and (b) inserting a cathode and an anode into the container.
The process allows for faster manufacturing of the battery containers. The process of cutting louvers in containers is faster than the process of punching holes into containers because no material is removed from the containers when louvers are cut. In addition, if burrs or surface discontinuities are produced from the cutting operation, they are located on portions of the can that do not contact the cathode surface.
As used herein, a “louver” means an opening or openings, having a leaf or tab, through which air can flow. When the louver is open on one side, the leaf is slanted. When the louver is open on both sides, the tab is substantially parallel to the outer surface of the container.
As used herein, a “louver opening” means the distance between the can and the edge of the leaf or tab of a louver.
As used herein, the “louver open area” means the length of the louver times the width of the louver opening, or openings in the case of louvers open on two sides.
Other features and advantages of the invention will be apparent from the description of the preferred embodiment thereof, and from the claims.


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Cretzmeyer et al., “Commercial Zinc-Air Batteries”, pp. 269-290 (No Date).
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