Granted Patent B2

US 10,128,509 · App. 14/935,634 · Granted Nov 13, 2018

Abstract

Claims (26)

1. A method for assembling an electrochemical cell system comprising:

providing a cell module configured to receive a liquid ionically conductive medium therein;

installing a fuel electrode configured to store a metal fuel therein into a cell chamber of the cell module;

providing a plate for the cell module;

installing a gas permeable and liquid impermeable membrane on the plate, wherein the gas permeable and liquid impermeable membrane has an inner surface facing the ionically conductive medium upon the installing and wherein the inner surface comprises a first portion and a second portion;

joining the plate and the cell module such that the ionically conductive medium is prevented from permeating therebetween;

wherein the fuel electrode and an oxidant electrode are configured to, during discharge, oxidize the metal fuel at the fuel electrode and reduce an oxidant at the oxidant electrode to generate a discharge potential difference therebetween for application to a load; and

wherein the gas permeable and liquid impermeable membrane is positioned along a portion of the cell module and configured to close the portion of the cell module to contain the ionically conductive medium therein; wherein the first portion of the gas permeable and liquid impermeable membrane does not have an oxidant electrode active material and provides a vent for the cell module to permit gas in the cell module to permeate therethrough for venting of the gas from the electrochemical cell system and the second portion of the gas permeable and liquid impermeable membrane has the oxidant electrode active material to comprise the oxidant electrode within the cell module, and wherein the joining of the plate and cell module results in the oxidant electrode being spaced from the fuel electrode.

2. The method of claim 1 , wherein the gas permeable and liquid impermeable membrane comprises a fluoropolymer material.

3. The method of claim 2 , wherein the fluoropolymer material comprises polytetrafluoroethylene.

4. The method of claim 1 , wherein the cell module contains a flow path for the liquid ionically conductive medium therein, the flow path being configured to facilitate a flow of the ionically conductive medium through the electrochemical cell system.

5. The method of claim 4 , wherein the gas permeable and liquid impermeable membrane is positioned down the flow path from the fuel electrode and the oxidant electrode, and configured to receive gas generated during electrochemical reactions at the fuel electrode and the oxidant electrode.

6. The method of claim 4 , wherein the gas permeable and liquid impermeable membrane is configured to contact the ionically conductive medium while the ionically conductive medium flows through the flow path.

7. The method of claim 1 , further comprising providing a charging electrode selected from the group consisting of (a) the oxidant electrode, (b) a separate charging electrode spaced from the fuel and oxidant electrodes, and (c) a portion of the fuel electrode.

8. The method of claim 7 , wherein the fuel electrode and the charging electrode are configured to, during re-charge, reduce a reducible species of the metal fuel to electrodeposit the metal fuel on the fuel electrode and oxidize an oxidizable species of the oxidant by application of a re-charge potential difference therebetween from a power source.

9. The method of claim 8 , wherein the fuel electrode comprises a series of permeable electrode bodies arranged in spaced apart relation;

wherein the spaced apart relation of the permeable electrode bodies enables the re-charge potential difference to be applied between the charging electrode and at least one of the permeable electrode bodies, with the charging electrode functioning as the anode and the at least one permeable electrode body functioning as the cathode, such that the reducible fuel species are reduced and electrodeposited as the metal fuel in oxidizable form on the at least one permeable electrode body, whereby 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 permeable electrode bodies.

10. The method of claim 8 , wherein the reducible species of the metal fuel comprises ions of zinc, iron, aluminum, magnesium, or lithium, and wherein the metal fuel is zinc, iron, aluminum, magnesium, or lithium.

11. The method of claim 1 , wherein the ionically conductive medium comprises an aqueous electrolyte solution.

12. The method of claim 11 , wherein the aqueous electrolyte solution comprises sulfuric acid, phosphoric acid, triflic acid, nitric acid, potassium hydroxide, sodium hydroxide, sodium chloride, potassium nitrate, or lithium chloride.

13. An oxidant electrode and vent assembly for an electrochemical cell comprising:

a gas permeable and liquid impermeable membrane comprising an inner surface having a first portion and a second portion; and

one or more oxidant electrode active materials provided on the first portion of the gas permeable and liquid impermeable membrane, but not the second portion of the gas permeable and liquid impermeable membrane;

wherein when the oxidant electrode and vent assembly is mounted to an electrochemical cell comprising a fuel electrode and a liquid ionically conductive medium both the first portion and the second portion of the inner surface face the ionically conductive medium such that the liquid ionically conductive medium contacts the one or more oxidant electrode active materials and the fuel electrode, the fuel electrode and the one or more oxidant electrode active materials are configured to, during discharge, oxidize the metal fuel at the fuel electrode and reduce a gaseous oxidant received through the gas-permeable and liquid impermeable membrane at the one or more oxidant electrode active materials, to generate a discharge potential difference therebetween for application to a load;

wherein at least the first portion of the gas permeable and liquid impermeable membrane is configured to prevent permeation of the ionically conductive medium out of the electrochemical cell and permit the gaseous oxidant to permeate into the one or more oxidant electrode active materials; and

wherein at least the second portion of the gas permeable and liquid impermeable membrane is configured to permit gas in the electrochemical cell to permeate therethrough for venting of the gas from the electrochemical cell, and prevent permeation of the ionically conductive medium out of the electrochemical cell.

Assignments (8)