ZINC-AIR BATTERY SYSTEMS AND METHODS

One aspect includes a zinc-air battery that includes a gas-permeable barrier sheet first layer, a cathode collector second layer disposed facing the gas-permeable barrier sheet first layer, a cathode puck third layer disposed facing the cathode collector second layer, a separator fourth layer disposed facing the cathode puck third layer, a zinc fifth layer disposed facing the separator fourth layer, an anode collector sixth layer disposed facing the zinc fifth layer; and a housing surrounding at least the first, second, third, fourth, and fifth layers and comprising a gas-permeable housing first end disposed facing the barrier sheet first layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1ais an exemplary perspective drawing illustrating an embodiment of a battery.

FIG. 1bis an exemplary perspective drawing illustrating the battery ofFIG. 1acoupled to a smartphone.

FIG. 2ais an exemplary perspective drawing illustrating the battery ofFIGS. 1aand 1bassociated with an adapter.

FIG. 2bis an exemplary perspective drawing illustrating the battery ofFIGS. 1a,1band2acoupled with the adapter ofFIG. 2aand associated with a power cord.

FIG. 3aillustrates an exploded perspective view of a battery in accordance with another embodiment.

FIG. 3billustrates a perspective view of the battery ofFIG. 3ain an assembled configuration.

FIG. 4aillustrates a perspective view of a frame of the battery ofFIGS. 3aand3b.

FIG. 4billustrates a cross-section perspective view of the frame ofFIG. 4a.

FIG. 5aillustrates a perspective view of a barrier of the battery ofFIGS. 3aand3b.

FIG. 5billustrates a cross-section perspective view of the barrier ofFIG. 5a.

FIG. 6illustrates a perspective view of the barrier and frame ofFIGS. 4aand4b.

FIG. 7aillustrates a perspective view of a cathode of the battery ofFIGS. 3aand3b.

FIG. 7billustrates a cross-section perspective view of the cathode ofFIG. 7a.

FIG. 8aillustrates an exploded perspective view of a zinc layer, anode collector and can of the battery ofFIGS. 3aand3b.

FIG. 8billustrates a perspective view of the zinc layer, anode collector and can ofFIG. 8ain an assembled configuration.

FIG. 9illustrates an exploded perspective view of a battery in accordance with a further embodiment.

FIG. 10illustrates a perspective view of the battery ofFIG. 9in an assembled configuration.

FIG. 11illustrates a cross sectional side view of the batteries ofFIGS. 9 and 10.

FIG. 12illustrates a cross sectional perspective view of an anode cap of the battery ofFIGS. 9, 10 and 11.

FIG. 13illustrates an exploded perspective view of a battery in accordance with another embodiment.

FIG. 14aillustrates a perspective view of the battery ofFIG. 13in an assembled configuration.

FIG. 14billustrates a cut-away perspective view of the battery ofFIGS. 13 and 14a.

FIG. 15illustrates an exploded perspective view of a battery in accordance yet another embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning toFIG. 1a,a battery100is shown in one example embodiment100A as comprising battery body105disposed in a cartridge110. The battery body105is shown having a face106comprising a plurality of vents107. The battery body105is disposed in a tray111defined by the cartridge110, which further defines a rim112that peripherally surrounds the face106of the battery body105on cartridge top and bottom ends113,114and cartridge sides115. The cartridge top end113comprises an elongated coupling slot116defined by the cartridge110that extends between the top and bottom face117,118of the cartridge110.

In various embodiments, the coupling slot116can correspond to a locking post120as illustrated inFIGS. 1b,2aand2b.Turning toFIG. 1b,the battery100can be configured to power various devices including a smartphone125, which is shown disposed in a battery case135, which can be configured to operably accept the battery100A in a case tray136defined by the battery case135. In other words, the battery100A can be configured to snap into the tray136and around the locking post120to deliver power to the smartphone125.

Accordingly, the example battery case135ofFIG. 1b,can be operably connected to the smartphone135such that when the battery100A is coupled with the case135, electrical power generated by the battery100A can be communicated to the smartphone125via the case135such that the battery100A powers the smartphone in part or in whole. For example, in some embodiments, the smart phone can comprise one or more power source (e.g., a battery) and the battery100A can provide additional power to the smart phone135and/or completely power the smartphone135.

As discussed in more detail herein, in various embodiments, a power system can comprise a plurality of batteries100that are configured to removably couple with various devices (e.g., smartphones) to provide power to such devices. Such a system can be configured to provide power to such devices when one or more device power source is exhausted or depleted.

For example, when a user is running out of battery power on his smartphone135, the user can attach a battery100A to the battery case135on the smartphone135to provide power to the smartphone135to extend the operating life of the smartphone135. Where a first battery100A becomes depleted or exhausted, the user can swap a second battery100A in place of the first battery100A to further extend the operating life of the smartphone135. Accordingly, by swapping out a plurality of batteries100A on the case135, the operating life of the smartphone135can be extended indefinitely, even if a battery of the smartphone135is depleted or exhausted.

Such a power system can be desirable because it can allow a user to continuously power a device without the necessity of charging a primary battery associated with the device. In some examples, a user can carry one or more battery100as a backup in case a primary battery associated with a device is depleted or exhausted and/or to replace depleted or exhausted backup batteries100. In further examples, batteries100can be available at retail locations, from street vendors, via vending machines, via drone, via courier, or the like. In various examples, a user can identify, via an application, people and/or retailers that can provide the user with one or more battery100. In some examples, batteries can be delivered to the user's location and/or the user can travel to a location where batteries are available.

Although a smartphone135is discussed as a device that can be powered by such a power system and/or battery100, in further embodiments, any suitable device can be powered by a battery100, including a tablet computer, a laptop computer, a smartwatch, a headset computer, a virtual reality system, a gaming device, a vehicle, a drone, an audio player, a body monitor, a work tool, or the like. Accordingly, in various embodiments, batteries100can take on various suitable sizes, shapes, and types. Some specific embodiments of batteries100having flat prismatic shape are described in the present disclosure, but should not be construed to be limiting on the wide variety of batteries100that are within the scope and spirit of the present invention.

Turning toFIGS. 2aand2b,for example, the battery100A ofFIGS. 1aand 1bcan be configured to operably couple with an adapter200. The adapter100can be configured to directly interface with one or more devices to provide power to the device, or as shown inFIG. 2b,the adapter200can be configured to provide power to various devices via a power cord250that can couple with the adapter200. In further examples, the adapter200can be configured to provide power to various devices wirelessly via inductive coupling, or the like.

In various examples, the adapter200can comprise a coupling rim205that comprises the locking post120disposed on a shelf206. The shelf206can be perpendicular to a back wall207. As illustrated inFIG. 2a,the coupling slot116can engage the coupling rim205and the top end113of the battery100A can engage the back wall207, with a portion of the rear face118of the battery100A engaging the shelf206.

FIGS. 1a,1b,2aand2billustrates an example battery100A that is planar and rectangular with rounded corners and having a single elongated coupling slot116that extends parallel to the top end of the battery100A. However, further embodiments can be of any suitable shape and size. Further embodiments can comprise a plurality of coupling slots116, or a coupling slot116can be absent. Additionally, various suitable coupling structures can be present on a battery100in some embodiments.

In various embodiments, it can be desirable for devices, adapters and/or batteries of a power system to have complementary coupling structures. For example, in some embodiments, complementary coupling structures can provide for standardized couplings that can be the basis for a proprietary power system. In some embodiments, various complementary couplings can provide for batteries of a certain power profile (e.g. voltage and/or ampere output) to only be coupled with devices and/or adapters that are configured for that battery. In other words, batteries100having different power profiles can have different complementary couplings.

Additionally, in various embodiments, batteries100can be of any suitable battery type and may or may not be rechargeable. For example, a battery100can comprise a lead acid battery, a lithium ion battery, a nickel metal hydride battery, a zinc-air battery, or the like. The following discussion illustrates some examples of zinc-air batteries in accordance with various embodiments, but such disclosure should not be construed to be limiting on the many types of batteries that are within the scope and spirit of the present invention.

FIGS. 3aand 3billustrate a battery100in accordance with one example embodiment100B. The battery100B is shown comprising a plurality of layered elements including a frame310, a barrier320, a cathode330, a separator340, a zinc layer350, an anode collector360, and a can370.

As illustrated inFIGS. 3a,3b,4a,4band6the frame310can comprise a cathode exit311defined by an outer wall405of the frame310. In this example, as shown in the cross sectional view ofFIG. 4b,the frame310can have an L-shaped cross section defined by an outer wall lip410that extends perpendicularly to a flange portion415that extends into and defines an orifice312. The lip410and flange portion415can define a notch420. The frame can comprise various suitable materials, including plastics such as polypropylene (PP), or the like. The frame310can be made in any suitable way, including injection molding, or the like.

As illustrated inFIGS. 3a,3b,5a,5band6, the barrier320can comprise a planar barrier sheet321having an adhesive322disposed about the edge510of a first face515of the barrier sheet321. The barrier sheet321can comprise various suitable materials in various embodiments. In some embodiments, it can be desirable for the barrier sheet to comprise a material that is not liquid transmissive, but is gas transmissive. In other words, in some embodiments, the barrier sheet321can allow various gasses to pass through the barrier sheet321(e.g., between a first and second face515,520), but prevent liquids such as water from passing through the barrier sheet321. As discussed in more detail herein, a gas transmissive barrier sheet321can be desirable because it can provide for functioning of the battery100B by allowing various gasses to contact internal portions of the battery100B to generate an electrical current. In some preferred embodiments, the barrier sheet321can comprise polytetrafluoroethylene (PTFE), ePTFE (proprietary polytetrafluoroethylene by W. L. Gore & Associates), and the like.

The adhesive322can comprise any suitable adhesive, including a glue, wax, epoxy, acrylic, silicone, rubber, VHB (3M, Inc.) or the like. For example, in one preferred embodiment, the adhesive322can comprise a pressure sensitive adhesive (PSA) or epoxy. As illustrated inFIG. 6, the barrier320can be configured to reside within the notch420defined by the frame310. Additionally, the adhesive322can be configured to couple with the notch320via the lip410and/or flange portion415that define the notch320. In some embodiments, a width of the adhesive322can correspond to a width of the flange portion415, such that the adhesive does not substantially extend into the orifice312defined by the frame310.

Additionally, in various embodiments, a thickness of the adhesive322and barrier sheet321can correspond to the cathode exit311defined by the outer wall405of the frame310. For example, the thickness of the adhesive322and barrier sheet321can allow the adhesive322and barrier sheet321to reside within the notch320of the frame310, without the adhesive322and barrier sheet321obstructing the cathode exit311. In further embodiments, the barrier sheet321can be coupled to the frame310via an ultrasonic weld or other suitable coupling method.

As illustrated inFIGS. 3a,3b,7aand7bthe cathode330can comprise a cathode collector plate331that includes a cathode terminal332and a cathode puck333. In various embodiments, the cathode collector plate331can comprise any suitable metal or other conductive material. For example, in one preferred embodiment, the cathode collector plate331can comprise nickel. The cathode collector plate331can be in various suitable configurations and formed in various suitable ways in accordance with various embodiments. For example, in some embodiments, the cathode collector plate331can comprise a mesh that is configured to allow gas, fluid or other matter to pass through the collector plate331and contact the cathode puck333. For example, in various embodiments, having a mesh collector plate331can be desirable so that air can reach the cathode puck333to facilitate a chemical reaction for generating electrical current.

The cathode puck333can comprise various suitable materials in various embodiments. For example, in one preferred embodiment, the cathode puck333can comprise carbon, manganese, and polytetrafluoroethylene (PTFE). In another preferred embodiment, the cathode puck333can comprise catalytic carbon manganese dioxide.

As illustrated inFIGS. 3a,3b,8aand8bthe battery100B can comprise a zinc layer350, an anode collector360, and a can370.FIGS. 3aand 8aillustrate an exploded view of the zinc layer350, anode collector360, and can370andFIG. 8billustrates a cross sectional view of the zinc layer350, anode collector360, and can370in an assembled configuration. As shown inFIG. 8b,the anode collector360can be disposed within a tray374of the can370and can engage a base375of the can370. The anode collector360can comprise an anode terminal361, which can extend through an anode terminal slot371defined by the can370. The zinc layer350can be disposed within the tray374of the can370over the anode collector360.

In various examples, the zinc layer350can comprise a zinc slurry. For example, in one embodiment, the zinc layer350can comprise a semiliquid mixture of zinc particles suspended in potassium hydroxide or other suitable liquid. The anode collector360can comprise various suitable materials, including conductive materials such as metals. For example, in one preferred embodiment, the anode collector360can comprise brass.

The separator340(FIG. 3a) can be disposed over the zinc layer350in the tray374of the can370. The separator340can comprise various suitable materials. The separator340can be rigid or flexible in some embodiments. Additionally, in some embodiments, the separator340can be fluid, gas and/or liquid permeable, semi-permeable or non-permeable. In various embodiments, it can be desirable to select a material for the separator340that is thin and wets well. In some embodiments, the separator can comprise a fabric, paper, or the like that can comprise non-woven wood pulp and/or synthetic fibers which may or may not be reinforced with a binder. For example, in one preferred embodiment, the separator340can comprise a KimWipe Wiper (Kimberly-Clark Professional, Inc.).

As illustrated in exploded view ofFIG. 3a,the cathode330can be layered on the separator340, with the frame310and barrier320layered on the cathode330. The cathode terminal332can extend through the cathode exit311defined by an outer wall405and a cathode slot defined by the can370. In various embodiments, the frame310can be configured to engage a shelf373defined by can370such that a top face of the frame310is parallel to a top face of a rim of the can370. The frame310can be coupled to the can via a weld, adhesive, friction fit, or other suitable coupling method. An example assembled battery100B is illustrated inFIG. 3b.

FIGS. 9-12illustrate a battery100in accordance with another embodiment100C. As illustrated inFIG. 9, the battery100C can comprise a cathode can910that comprises a tray911defined by a rim912and a base913of the tray910. As illustrated inFIGS. 9 and 13, in some embodiments, the base913of the cathode can910can comprise a plurality of ports or holes914that extend through the base913.

A barrier sheet921can be coupled to the base913of the cathode can910via an adhesive922. In some examples, the adhesive922and/or barrier sheet921can comprise any of the materials or be configured like the adhesive322and barrier sheet321discussed above. For example, in one embodiment, the barrier sheet921can comprise ePTFE and the adhesive922can comprise an epoxy or pressure sensitive adhesive.

A cathode collector931can be positioned over the barrier sheet921and a cathode puck933can be positioned over the cathode collector. In some embodiments, the cathode collector931and/or cathode puck933can comprise any of the materials or be configured like the cathode collector331and/or cathode puck333discussed above. For example, the cathode collector931can comprise a nickel mesh and the cathode puck933can comprise carbon, manganese, and/or polytetrafluoroethylene (PTFE). In another example, the cathode puck933can comprise catalytic carbon manganese dioxide.

A separator940can be positioned over the cathode puck933and a zinc layer950can be positioned over the separator940. In some embodiments, the separator940and/or a zinc layer950can comprise any of the materials or be configured like the separator340or zinc layer350discussed above. For example, the separator940can comprise a KimWipe material and the zinc layer940can comprise a zinc slurry having zinc particles suspended in a liquid such as potassium hydroxide, or the like.

An anode cap970can be positioned over the zinc layer950and engage a portion of the rim912of the can910within the tray911. For example, the anode cap970can comprise a gasket980that surrounds an edge of an anode body985of the anode cap970, and the gasket can engage a portion of the rim912of the can910within the tray911via friction fit, or the like. In various embodiments, the anode body985can comprise any suitable material including a metal. For example, the anode body985can comprise nickel, stainless steel plated with nickel and the like. The gasket980can comprise any suitable material including rubber, silicone, a plastic, or the like.FIG. 10illustrates an example perspective view of an assembled battery100B, including the anode cap970engaging the rim912can910via the gasket980.

FIG. 11illustrates an example cross section of the battery100C, which shows a top outer layer defined by the anode body985of the anode cap970. The anode body985is shown inFIGS. 11 and 12comprising a planar cap top1186with rim1187extending away from and perpendicular to the cap top1186, the rim1187is shown over-molded with the gasket980and comprising a terminal curl1188that can serve to fix the gasket980in place over the rim1188.

The cathode can910engage the gasket980via a lip1115defined by the rim912of the cathode can910. The gasket980further extends downward and engages the cathode collector931along a portion of a cathode collector base1132and a cathode collector rim1133that extends upward and perpendicularly away from the cathode collector base1132. The planar cap top1186, the gasket980and the cathode collector931define a cavity1101, wherein the zinc layer950, the separator940, and cathode puck933are disposed. More specifically, the zinc layer950is disposed on the separator940, and the separator is disposed on the cathode puck933, which is disposed on the collector base1132of the cathode collector931.

The cathode collector931engages the rim912of the cathode can910to collectively form an anode1102. An anode cavity1103is defined between the cathode collector base1132and the cathode can base913. The barrier921and adhesive922are disposed within the anode cavity1103with the adhesive922coupling an edge of the barrier921. In various embodiments, the cathode collector931can apply pressure to the barrier921and adhesive922, which can be desirable for generating a better seal between the barrier921, adhesive922, and cathode can910.

As illustrated inFIG. 11, in various embodiments, gas can penetrate the battery100C via the one or more ports914defined by the can base913and reach the cathode puck933. Allowing gas, such as air or the like, to reach the cathode puck933can be desirable because it can provide for a chemical reaction between the gas and the cathode puck933, which can facilitate generation of an electrical current.

As discussed herein and as illustrated inFIG. 9the adhesive922can be disposed on an outer edge of the barrier921, which exposes a portion of the barrier921to gas entering the ports914. The barrier921can be configured to be gas permeable, which can allow the gas to pass through the barrier921. In some embodiments, the barrier can be configured to be non-transmissive for liquids, solids and the like. Additionally, the cathode collector931can comprise a mesh configuration, or the like, which can provide a plurality of passages through the cathode collector931. Accordingly, gas can pass through the cathode collector931and contact the cathode puck933to facilitate a chemical reaction to generate electrical current.

FIGS. 13, 14aand14billustrate another embodiment of a battery100in accordance with another embodiment100D. The battery100D comprises a chassis1370, that comprises a tray1371defined by a rim1372and a base1373of the tray1371. The chassis1370can also comprise one or more fill port1374, in which a respective plug1375can reside. The chassis1370can also comprise respective cathode an anode terminal ports1376,1377and a coupling slot.

The battery100D can also comprise an anode collector1360that includes an anode terminal1360. The anode collector1360can reside at the base1373of the chassis1370within the tray1371, with the anode terminal1360extending into and/or through the anode terminal port1377. In some embodiments, the anode collector1360can comprise any of the materials or be configured like the anode collector360discussed above and illustrated inFIG. 3. For example, in one preferred embodiment, the anode collector1360can comprise brass.

A zinc layer950can be positioned over the anode collector1360. In some embodiments, zinc layer950can comprise any of the materials or be configured like zinc layers350,950discussed above. For example, the zinc layer can comprise a zinc slurry having zinc particles suspended in a liquid such as potassium hydroxide, or the like.

A cathode1330can be positioned over the zinc layer950and can comprise a cathode collector plate1331that includes a cathode terminal1332and a cathode puck1333. The cathode1330can reside within the tray1373of the chassis1370with the cathode terminal1332extending through the cathode terminal port1376.

In various embodiments, the cathode collector plate1331can comprise any suitable metal or other conductive material. For example, in one preferred embodiment, the cathode collector plate1331can comprise nickel. The cathode collector plate1331can be in various suitable configurations and formed in various suitable ways in accordance with various embodiments. For example, in some embodiments, the cathode collector plate1331can comprise a mesh that is configured to allow gas, fluid or other matter to pass through the collector plate1331and contact the cathode puck1333. For example, in various embodiments, having a mesh collector plate1331can be desirable so that air can reach the cathode puck1333to facilitate a chemical reaction for generating electrical current.

The cathode puck1333can comprise various suitable materials including carbon, manganese, and/or polytetrafluoroethylene (PTFE). For example, in one embodiment the cathode puck1333can comprise catalytic carbon manganese dioxide. In some embodiments the cathode puck1333can comprise a wetting or separator layer, which can comprise a fabric, paper, or the like. For example, in some embodiments, the cathode puck1333can comprise a separator340,940as discussed above, and such a separator can be disposed between the cathode puck1333and the zinc layer1350.

A barrier sheet921can be positioned over the cathode puck1333. In some examples, the barrier sheet921can comprise any of the materials or be configured like the barrier sheet321,921discussed above. For example, in one embodiment, the barrier sheet1321can comprise ePTFE or PTFE.

A cover1310can be positioned over the barrier sheet1321and include a top1311that defines a plurality of holes or ports1312that extend through the top1311. The cover1310can further comprise a pair of arms1313that are configured to couple with respective coupling slots1387defined by the rim1372of the chassis1370. The cover1310can be configured to seal the elements between the chassis base1373and cover1310within the tray1371of the chassis1370. The cover1310and/or chassis1370can comprise any suitable materials including a plastic, metal, or the like.

In some embodiments, a battery100can comprise a plurality of battery cells in contrast to a single battery cell as described in embodiments100B-D. For example,FIG. 15illustrates another embodiment100E of a battery100that comprises a plurality of battery cells1501that comprise a plurality of battery layers1502. The cells1501can comprise a configuration like any of the batteries described above in embodiments100B-D.

For example, the plurality of layers1502of the cells1501can include a cathode collector1531, a cathode puck1533, one or more separator1540, a zinc layer1550, and an anode collector1560. In the example ofFIG. 15, the battery100E includes four cells1501; however, in further embodiments, and suitable plurality of cells or a single cell can be implemented. For example, some embodiments can have one, two, three, five, six, seven, eight, nine or ten cells.

The cells1501can be configured to reside within slots1504,1506defined by a respective reinforcing frame1503and cell walls1505. The cells1501, frame1503and cell walls1505can be surrounded by a barrier sheet1521, a cell backing1507, a chassis1570, one or more cap1508, and a cover1510. The cover1510can be positioned over the barrier sheet1521and include a top1511that defines a plurality of holes or ports1512that extend through the top1511. The cover1510can further comprise a pair of arms1513that are configured to couple with a rim1572of the chassis1570. The cover1510can be configured to seal the cells1501between the chassis1570and cover1310.

The chemical and hardware elements of batteries100can comprise any suitable configuration that provides for generation of an electrical current. Additionally, while the example, of a zinc-air battery is used herein, it should be clear that alternative battery types, chemistries, and battery configurations are also within the scope and spirit of the present disclosure.

In various embodiments, a zinc layer350,950,1350,1550can include various suitable compositions. For example, a zinc layer350,950,1350,1550can comprise a slurry or gel that includes of a blend of amalgamated zinc grains and potassium hydroxide. In one example, a potassium hydroxide electrolyte gel can include 18 M-Ohm deionized water; zinc grains doped with indium and/or bismuth (e.g., Grillo Werk Aktiengesellschaft, #000010-600376); carboxymethylcellulose and sodium salt (e.g., High Viscosity, Sigma CAS #9004-32-4); and potassium hydroxide 90%.

In one example, a zinc slurry or gel can be made by preparing a solution of 11 M potassium hydroxide and 1.6% wt carboxymethylcellulose and mixing 0.69% wt powdered zinc with 0.31% wt of the prepared solution. Further embodiments can employ suitable compositions, system and methods from U.S. Patent Publication US 2011/0123902 of U.S. application Ser. No. 12/919,214 filed May 26, 2011, which is hereby incorporated by reference in its entirety and for all purposes.

The described embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the described embodiments are not to be limited to the particular forms or methods disclosed, but to the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives.