Anode can for a metal-air cell

Details Anode can for a metal-air cell Anode can for a metal-air cell

1998-11-12

2001-07-24

Kalafut, Stephen (Department: 1745)

Chemistry: electrical current producing apparatus, product, and

With pressure equalizing means for liquid immersion operation

C429S149000, C429S166000

Reexamination Certificate

active

06265094

ABSTRACT:

TECHNICAL FIELD
The present invention relates to a metal-air battery cell and more particularly relates to an anode can that functions both as the metal anode and as the container for the metal-air cell itself.
BACKGROUND OF THE INVENTION
Generally described, a metal-air cell, such as a zinc-air cell, uses an air permeable cathode separated from a metallic zinc anode by an aqueous electrolyte. During operation of the cell, oxygen from the ambient air is converted at the cathode to produce hydroxide ions while the metallic zinc is oxidized at the anode to react with the hydroxide ions. Water and electrons are released in this reaction to provide electrical energy.
As compared to conventional types of electrochemical cells, metal-air battery cells provide relatively high power output and lifetime with relatively low weight. These advantages are due in part to the fact that metal-air cells utilize oxygen from the ambient air as a reactant in the electrochemical process rather than a heavier material such as a metal or metallic composition. One drawback, however, with the current design of metal-air cells is that the cells tend to be somewhat larger in size than conventional electrochemical cells. This size constraint is caused by the requirement of having an anode, a cathode, an electrolyte, a cell casing of some sort, and an air passageway to provide reactant air to the cell. For example, a typical metal-air “button”-type cell is found in U.S. Pat. No. 5,451,473, showing an anode can or container, a metal zinc gel or powder within the anode can, a cathode can, an air cathode within the cathode can, an air passageway with an air membrane, and several internal support and sealing structures. Each of these elements is necessary for the cell to operate and requires a certain amount of space.
Although metal-air cells are preferred because of the higher power output, longer life, and lower weight as compared to conventional electrochemical cells, the size of typical metal-air cells has prevented wide spread use of such metal-air cells in many types of applications. There is a need, therefore, for a metal-air cell with a reduced size but with the traditional metal-air advantages and capabilities. In other words, a metal-air cell in the size and shape of a conventional electrochemical cell. Such a cell would have broad availability for many different types of applications. These goals must be accomplished in a cell that remains light-weight and relatively inexpensive for wide spread consumer use.
SUMMARY OF THE INVENTION
Generally described, the present invention provides a metal-air cell with an anode container. The anode container is made from a reactive metal. The metal-air cell also has an absorbent layer with a first side and a second side. Electrolyte is substantially trapped within the absorbent layer. The first side of the absorbent layer is positioned in contact with the anode container and an air electrode is positioned in contact with the second side of the absorbent layer. Specific embodiments of this invention include the anode container in the shape of a can. The container is made from a zinc metal or a zinc alloy metal.
Other specific embodiments of the present invention include positioning the absorbent layer within the anode container. The absorbent layer may be made from a nylon or similar materials. The electrolyte may be potassium hydroxide or similar fluids. The metal-air cell also may include a gasket positioned between the anode container and the air electrode such that the anode container and the air electrode are not in physical contact with each other. The gasket may be made from a nylon or similar materials.
The metal-air cell herein also may include an air mask enclosing the anode can. The air mask may have an open area of about one to five percent. The air mask provides a gas mixing area for the ambient air that has seeped into the cell. The air mask may be a nickel-plated steel or similar types of conductive materials. The air mask also may be made from a plastic with a metal plate or plating. Alternatively, the cell may use a cathode tab.
Finally, the metal-air cell also may have a thin film substantially covering the outside of the anode container to prevent the container from leaking electrolyte. The thin film may be made from a polyester or similar types of electrolyte impervious materials.
The metal-air cell of the present invention may be used on its own like a conventional button cell or as part of a multi-cell battery pack positioned within a housing. The battery pack may use an air manager in association with the housing to provide reactant air thereto.
For example, a thin metal-air battery may have a substantially rigid container with a plurality of cell compartments formed therein and sharing a common floor and one or more common walls. Each cell compartment has an air electrode positioned therein to form a plurality of metal-air cells. A cover then encloses the container. The container itself is made from a reactive metal such as zinc. Alternatively, a metal anode may be positioned within the container. An air manager may be positioned adjacent to or within the container.
It is thus an object of the present invention to provide an anode can for a metal-air cell.
It is a further object of the present invention to provide an anode that functions as a cell container for a metal-air cell.
It is another object of the present invention to provide a thin metal-air cell.
It is yet another object of the present invention to provide a thin metal-air cell with improved power, weight, and lifetime characteristics as compared to a conventional electrochemical cell.
It is yet another object of the present invention to provide an improved metal-air button cell.
It is still another object of the present invention to provide an improved metal-air cell.
It is an even further object of the present invention to provide a thin metal air battery with cells sharing a common casing.


REFERENCES:
patent: 3023259 (1962-02-01), Coler et al.
patent: 3026365 (1962-03-01), Hughes et al.
patent: 3630783 (1971-12-01), Przybyla
patent: 3746580 (1973-07-01), Aker et al.
patent: 3853629 (1974-12-01), Elliott
patent: 3881959 (1975-05-01), Tsuchida et al.
patent: 3920477 (1975-11-01), Alaburda
patent: 4105830 (1978-08-01), Kordesch
patent: 4242424 (1980-12-01), Buckler et al.
patent: 4262062 (1981-04-01), Zatsky
patent: 4333993 (1982-06-01), Gibbard
patent: 4343869 (1982-08-01), Oltman et al.
patent: 4404266 (1983-09-01), Smilanich
patent: 4461812 (1984-07-01), Mascioli
patent: 4535036 (1985-08-01), Kelm et al.
patent: 4551399 (1985-11-01), Despic
patent: 4585710 (1986-04-01), McEvoy
patent: 4664994 (1987-05-01), Koike et al.
patent: 4957826 (1990-09-01), Cheiky
patent: 4965147 (1990-10-01), Mas et al.
patent: 5306578 (1994-04-01), Ohashi et al.
patent: 5356729 (1994-10-01), Pedicini
patent: 5432022 (1995-07-01), Cheiky
patent: 5451473 (1995-09-01), Oltman et al.
patent: 5458988 (1995-10-01), Putt
patent: 5547781 (1996-08-01), Blonsky et al.
patent: 5560999 (1996-10-01), Pedicini et al.
patent: 5567538 (1996-10-01), Oltman et al.
patent: 5582930 (1996-12-01), Oltman et al.
patent: 5582932 (1996-12-01), Oltman et al.
patent: 5605774 (1997-02-01), Ekern et al.
patent: 5654110 (1997-08-01), Tuttle et al.
patent: 5663014 (1997-09-01), Blonsky et al.
patent: 5691074 (1997-11-01), Pedicini
patent: 5705294 (1998-01-01), Lake
patent: 5716726 (1998-02-01), Cheiky
patent: 5733677 (1998-03-01), Golovin et al.
patent: 0 741 427 A1 (1996-11-01), None
“Air-Cathode with Zinc Anodes Make High-Energy Density Batteries” Mar. 1979 Electronic Design.

Affiliated with

Also associated with

Rating

Anode can for a metal-air cell does not yet have a rating. At this time, there are no reviews or comments for this patent.

If you have personal experience with Anode can for a metal-air cell, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Anode can for a metal-air cell will most certainly appreciate the feedback.

Rate now

Comments { 0 }

Profile ID: LFUS-PAI-O-2523662