BATTERY POWERED LIGHT SOURCE

Abstract: A battery powered light source comprising an electric light bulb; a plurality of air cathodes (34); a plurality of metal anodes (36), one for each cathode; a plurality of electrically nonconductive housings (16/18) disposed adjacent to each other, wherein each housing encloses a respective chamber (22) containing one cathode and one anode which are spaced from each other and form an anode-cathode pair and also encloses a cavity (22a) which is below the anode-cathode pair and is in fluid flow communication with the chamber, each housing having a portion defining at least one air passage (32) from its chamber to an adjacent housing, and an opening (28) through which a surface of the contained cathode is exposed to air in the passage. The housings (16/18) are secured to each other in such arrangement that their respective air-passage-defining portions co-operatively define at least one common air passage. Circuit elements are provided for electric­ ally connecting the anode-cathode pairs to each other and to the electric light bulb.

Description: Background of the Invention The invention relates to a battery powered light source and to applications thereof. Our invention is useful as an inexpensive and convenient means for providing light for an extended period of time. It is useful, for example, on barges in the shipping industry. Battery powered light sources of the present invention can power a light bulb that emits light in accordance with the United States Coast Guard regulations for a period of about 28 days. Metal/air batteries produce electricity by the electrochemical coupling of a reactive metallic anode to an air cathode through a suitable electrolyte in a cell. As is well known in the art, an air cathode is a typically sheetlike member, having opposite surfaces respectively exposed to the atmosphere and to the aqueous electrolyte of the cell, in which (during cell operation) atmospheric oxygen dissociates while metal of the anode oxidizes, providing a usable electric current flow through external circuitry connected between the anode and cathode. The air cathode must be permeable to air but substantially hydrophobic (so that aqueous electrolyte will not seep or leak through it), and must incorporate an electrically conductive element to which the external circuitry can be connected; for instance, in present-day commercial practice, the air cathode is commonly constituted of active carbon (with or without an added dissociation-promoting catalyst) containing a finely divided hydrophobic polymeric material and incorporating a metal screen as the conductive element. A variety of anode metals have been used or proposed; among them, alloys of aluminum and alloys of magnesium are considered especially advantageous for particular applications, owing to their low cost, light weight, and ability to function as anodes in metal/air batteries using neutral electrolytes such as sea water or other aqueous saline solutions. Thus, by way of more specific example, an illustrative aluminum/air cell comprises a body of aqueous saline electrolyte, a sheetlike air cathode having one surface exposed to the electrolyte and the other surface exposed to air, and an aluminum alloy anode member (e.g. a flat plate) immersed in the electrolyte in facing spaced relation to the first-mentioned cathode surface. The discharge reaction for this cell may be written 4Al + 3O₂ + 6H₂O→4Al(OH)₃. As the reaction proceeds, copious production of the aluminum hydroxide reaction product (initially having a gel-like consistency) in the space between anode and cathode ultimately interferes with cell operation, necessitating periodic cleaning and electrolyte replacement. The cell may be recharged mechanically by replacing the aluminum anode when substantial anode metal has been consumed in the cell reaction. Metal/air batteries have an essentially infinite shelf-storage life so long as they are not activated with electrolyte, making them very suitable for standby or emergency uses. For example, an emergency lamp or lantern can be constructed with a metal/air battery such as an aluminum/air battery, and a separate container of electrolyte can be stored with the battery, or be readily available within its intended environment of use. When a need for use of an emergency light arises, a user can merely activate the metal-air battery (by simply adding electrolyte) and be provided with useful light. Hamlen et al., United States Patent No. 4,626,482, issued December 2, 1986, discloses a metal/air battery having plural series-connected cells, including a tank for holding a body of liquid electrolyte, and an electrically nonconductive frame carrying a plurality of air cathodes facing a common air chamber and a like plurality of metal anodes respectively juxtaposed to the cathodes outside the air chamber, the frame being removably insertable in the tank and engaging the tank wall, when inserted, so as to divide the tank into a plurality of separate and substantially electrically isolated electrolyte-holding zones each containing one anode-cathode pair. It is current industry practice to power lights with dry cell batteries which after a few nights are incapable of powering a light bulb. Depleted dry cell batteries are discarded each night or every other night and replaced with new dry cell batteries. Dry cell batteries are also inconvenient in that they often contain mercury which produces a toxic reaction product and have a short shelf-life as compared to the battery of the present invention. Batteries of the present invention are desirable because they overcome the deficiencies of dry cell batteries currently used on barges in the shipping industry. US-A-2,207,734 describes an electric cell comprising electrodes in contact with an electrolyte housed within a container. At least one of the electrodes is porous and has a surface in contact with a dry chamber below the level of the electrolyte and communicating with the atmosphere. US-A-4,184,008 describes a float-type metal-air battery having a centrally positioned air chamber whose walls are partly defined by respective cathodes of a pair of cells positioned on opposite sides of the air chamber. One surface of each cathode faces into the air chamber, the other is in contact with the electrolyte. In accordance with the invention, there is provided a battery powered light source comprising: (a) an electric light bulb; (b) a plurality of air cathodes; (c) a plurality of metal anodes, one for each cathode; (d) a plurality of electrically nonconductive housings disposed adjacent to each other; (e) wherein each housing comprises two electrically nonconductive shells having vertical edges joined to form a vertical seam and enclosing a respective generally rectangular chamber for holding liquid electrolyte, said chamber containing one activated carbon cathode and one anode formed of magnesium, aluminium or alloys thereof, said cathode and anode being spaced from each other to form an anode-cathode pair, for electrolytic reaction with said electrolyte producing an insoluble reaction product, each housing having a vertical wall with an interior side, means projecting from said interior side of the vertical wall to support a said anode and an opening in said vertical wall covered by a said cathode with said cathode being sealed to the interior side thereof, the chamber in each said housing further defining a cavity below the anode-cathode pair and in fluid flow communication with the chamber for collecting said reaction product, said cavity having sufficient capacity to contain the reaction product generated during battery use, and said housings being connected by said vertical walls to form at least one air passage connected exteriorly with the atmosphere and extending from one side of said housings to the opposite side adjacent said vertical wall openings whereby a surface of the cathode contained in each housing is exposed to air in said passage. In one embodiment of the present invention, the battery powered light source additionally comprises an electric light bulb which is electrically connected by circuit means to the anode-cathode pairs. In another embodiment of the present invention, the plurality of air cathodes is two, the plurality of metal anodes is two, the plurality of electrically nonconductive housings disposed adjacent to each other is two, and the battery powered light source additionally comprises an electric light bulb which is electrically connected by circuit means to the anode-cathode pairs. Further features and advantages of the invention will be apparent from the detailed description hereinbelow set forth, together with the accompanying drawings. Brief Description of the Drawings Fig. 1 is a perspective view of a barge light device embodying the present invention in a particular form; Fig. 2 is an exploded perspective view, partly broken away, of one cell of the device of Fig. 1; Fig. 3 is an enlarged sectional elevational view taken along the line 3-3 of Fig. 1; Fig. 4 is a similarly enlarged elevational view of the interior of one cell, taken along the line 4-4 of Fig. 1; and Fig. 5 is a further enlarged detail sectional view of the region enclosed by broken-line circle 5 in Fig. 3. In a preferred embodiment of the present invention, the metal anode is aluminum. Aluminum is conveniently light-weight and inexpensive. It has an indefinite shelf-life and efficiently reacts with oxygen to produce electricity. The metal may also be magnesium, or an alloy containing suitable amounts of aluminum, magnesium or mixtures thereof. Zinc is not a suitable metal for the present invention because dangerous caustic electrolyte is necessary to promote an efficient electrochemical reaction. The anode preferably has vertical slots which are effective in promoting egress of reaction product from, and sufficient electrolyte flow into and through, the gap or space between the anode and cathode to retard accumulation of reaction products therein. The anode may be separated from the cathode by a distance of about 1.5 mm to about 5 mm apart. A preferred distance is about 1.5 mm to about 10 mm , more preferably about 3 mm to about 10 mm, and a most preferred distance is about 3 mm to about 6 mm , for advantageous efficiency without undue shortening of useful operating time because of accumulation of electrochemical reaction product. In a preferred embodiment, the anode plate is shaped so that scrap is minimized when the anode plate is cut. In a preferred embodiment, the anode weighs about 200 grams. The anode plate is essentially a rectangular shape with a narrow arm extended from one long side of the rectangle, and an indentation, similar in shape to the narrow arm, opposing the narrow arm and indenting the anode plate from the opposite long side. The cavity positioned below the anode-cathode pair has sufficient capacity to contain electrochemical reaction product generated during battery use. By removing the reaction product from the area surrounding the anode-cathode pair, internal resistance is minimized and the electrochemical reaction proceeds efficiently. The presence of the cavity allows batteries of the present invention to have extended reaction activity. The battery powered light source is activated by filling each chamber to a suitable level with a saline solution or other aqueous electrolyte. Liquid electrolyte useful in the present invention may be any one of those electrolytes commonly used in batteries. The liquid electrolyte is water containing an additive to enhance electrical conductivity. The additive may be sodium chloride, potassium chloride, ammonium chloride, sodium hydroxide, potassium hydroxide or ammonium hydroxide. Sodium chloride is preferred because it is relatively convenient and inexpensive. Each housing of the present invention has a vertical wall having an interior side facing the chamber. The source includes means to support each anode in its respective chamber comprising one or more platforms which project from the interior side of the vertical wall of the housing and form flat horizontal surfaces on which the anode rests. An activated carbon plate is glued to the interior side of the vertical wall to form the cathode. Each housing comprises two electrically nonconductive shells having vertical edges joined to form a vertical seam. Joining shells to form a vertical seam is an efficient, cost-effective manner of constructing the housing. Use of expensive large-cavity molds is not necessary when the housing is constructed by joining edges of two shells formed from shallow molds. In a preferred embodiment of the present invention, the battery powered light source has means to control air flow into the common air passage or passages. Control of air flow is important in minimizing water evaporation which might reduce the extent of the electrochemical reaction and hence the life of the battery. In another embodiment of the present invention, the battery powered light source has means to alternately halt and recommence the electrochemical reaction. Thus, the life of a battery of the present invention having anode, cathode, and electrolyte to provide power sufficient to emit light of an intensity of 0.9 candela to a distance of 1.6 km from a light bulb continuously for about 28 days may be extended if said battery powered light source has means to alternately halt and recommence the electrochemical reaction. The means may be a switch such as a manual switch or a solar switch. Referring to the drawings, the invention is illustrated as embodied in a barge light device 10 comprising two essentially identical metal/air cells 11a and 11b and a cap member 12 shaped to provide a socket 14 for mounting an electrically energizable light source (not shown), e.g. an incandescent or other lamp, in a position such that the lamp projects above the cap member. The two cells and the cap are suitably glued or otherwise bonded together to constitute an effectively unitary structure. Each cell has a housing constituted of two facing, pan-shaped, molded plastic elements 16 and 18 glued or otherwise bonded together at their facing rims in a continuous sealed joint or seam 20 so as cooperatively to define a generally rectangular chamber 22 for holding a liquid electrolyte. The elements 16 and 18 respectively have major vertical walls 24 and 26, each extending from top to bottom and from end to end of the cell, disposed in generally parallel, spaced relation to each other, thereby to serve respectively as the outer and inner walls of the cell. Wall 26 is formed with an upper portion 26a having a large rectangular opening 28 across which extend a plurality of mullions 30; this portion 26a is recessed, from end to end of the cell, with respect to the wall portions 26b and 26c respectively above and below it. In the assembled device 10, the walls 26 of the two cells 11a and 11b are adhered together in facing contiguous relation to each other with their respective recessed portions 26a in register, forming a common laterally confined air passage 32 extending horizonally between, and open at each end of, the cells. The wall portion 26c of each cell may be formed with a horizontally spaced pair of respectively convex and concave dimples 26d for mating with the corresponding dimples of the other cell to facilitate assembly of the device. At the top of each cell housing element 16 there is provided a port 16a, closed by a plug 16b, for introduction of liquid electrolyte to the chamber 22; the plug may have a perforation or other vent opening (not shown) for release of gas generated by electrolytic reaction within the cell. Within the element 18 of each cell 11a or 11b, an air cathode 34 and a suitable metal (e.g. aluminum or aluminum alloy) anode 36 are disposed in facing, parallel, more or less closely spaced relation to each other (so as to define an anode-cathode gap G between them) with their facing surfaces exposed for contact with liquid electrolyte (not shown) in the chamber 22 of the cell. The air cathode is conveniently a generally rectangular sheet member fabricated of activated carbon, incorporating an electrically conductive material such as wire mesh; it is dimensioned and positioned to extend entirely over the opening 28 with its edges sealingly adhered to the interior surface of wall 26 all around the periphery of the latter opening so as to complete the liquid-tight enclosure of chamber 22, being supported externally by the mullions 30. Thus, while one major surface of the air cathode is exposed to liquid electrolyte within the cell, the other major surface of the air cathode is exposed (through the opening 28) to air in the air passage 32. The metal anode is a flat, generally rectangular metal plate of substantial thickness having a plurality of elongated vertical slots 36a opening through its major surfaces, and is supported at its lower edge on (and adhered to) a horizontally spaced pair of luglike projections 38 molded in the wall 26. At its top edge, the air cathode 34 has a vertically extending tab 34a projecting upwardly through a slot 40 in the top of the housing element 18. Similarly, the metal anode 36 has a tab 36b projecting upwardly through a slot 42 in the top of the same housing element. In the assembled cell, a suitable sealing material, is applied to close the slots around the tabs, and lead wires (not shown) are respectively secured to the exposed tab extremities above the housing element. For convenience and economy of manufacture, the metal anodes may be cut or punched in succession from an extended body of aluminum plate, with the tab 36b of each anode cut out of the body of the anode ahead of it, leaving a vertical notch 36c in the lower portion of the anode body. The dimension and disposition of the opening 28, air cathode 34, metal anode 36 and luglike projections 38 in each cell are chosen such that the lower edges of the cathode and anode are spaced substantially above the floor of the chamber 22. Consequently, each chamber 22 includes a cavity or reservoir portion 22a of substantial volume entirely below the cell electrodes, extending directly beneath the anode-cathode gap of the cell as well as outwardly thereof. This reservoir portion, at least equal in horizontal cross-sectional area to the upper (electrode-containing) portion of the chamber, has a vertical extent (below the electrodes) that may be as much as one-third, or even more, of the entire vertical extent of the chamber. The cap member 12 is a unitary, integral, molded plastic body, disposed above and extending entirely over the tops of the two cell housing elements 18 in the assembled device 10, thereby to enclose the tabs 34a, 36b and associated lead wires of both cells. Lateral flange portions 12a of the cap member respectively extend outwardly of, and in contiguous parallel relation to, the top portions of the seams 20 of the two cells, and are adhered thereto, while end flange portions 12b of the cap member substantially complete the enclosure of the electrode tabs and lead wires. Before the cap member is bonded to the cells 11a and 11b, the lead wires are connected between the cells and to terminals (not shown, but disposed within, i.e. under, the cap member) of a light source mounted in the cap member seat 14, so as to connect the cells and light source in a series circuit. These electrical connections are isolated from the cell interiors by the abovedescribed sealing of the slots 40 and 42 and are protected by the cap member when the latter is adhered to and over the cells 11a and 11b. The light source is supported by and projects above the cap mount 14 to provide desired illumination. In use, the device 10 may be activated by filling the chambers 22 of the two cells with salt water (e.g. sea water) or other appropriate electrolyte through the ports 16a, which are then closed; alternatively, if the device is provided with a switch (not shown) in the aforementioned circuit, it may be prefilled with electrolyte and turned on by operation of the switch. Assuming proper selection and configuration of the light source, and appropriate dimensioning of the cells and their electrodes (all matters readily within the ordinary skill of the art, given the foregoing description), a barge light designed to meet Coast Guard standards and having an advantageously long service lifetime is thereby provided. Reaction product such as aluminum hydroxide, formed in the anode-cathode gaps of the cells, passes downwardly from the gap and from the anode slots into the cavity or reservoir portion 22a of each cell chamber; the capacity of these cavities is such as to enable extended operation before the accumulating reaction product significantly interferes with cell operation. Air flows through the common lateral passage 32 defined between the cells, to permeate the air cathodes as required for the cells to operate, but because this passage is laterally confined between the two cells, the flow of air is limited or controlled, as desired to minimize evaporation losses of the liquid electrolyte in the cells. The device is simple and inexpensive yet sturdy and reliable in construction, and is easy to manufacture, assemble and use.

Claims: A battery powered light source comprising: (a) an electric light bulb; (b) a plurality of air cathodes (34); (c) a plurality of metal anodes (36), one for each cathode; (d) a plurality of electrically nonconductive housings (11a,11b) disposed adjacent to each other; (e) wherein each housing (11a,11b) comprises two electrically nonconductive shells (16,18) having vertical edges joined to form a vertical seam (20) and enclosing a respective generally rectangular chamber (22) for holding liquid electrolyte, said chamber containing one activated carbon cathode (34) and one anode (36) formed of magnesium, aluminium or alloys thereof, said cathode and anode being spaced from each other to form an anode-cathode pair, for electrolytic reaction with said electrolyte producing an insoluble reaction product, each housing having a vertical wall (26) with an interior side, means (38) projecting from said interior side of the vertical wall to support a said anode and an opening (28) in said vertical wall covered by a said cathode with said cathode being sealed to the interior side thereof, the chamber in each said housing further defining a cavity (22a) below the anode-cathode pair and in fluid flow communication with the chamber (22) for collecting said reaction product, said cavity having sufficient capacity to contain the reaction product generated during battery use, and said housings being connected by said vertical walls to form at least one air passage (32) connected exteriorly with the atmosphere and extending from one side of said housings to the opposite side adjacent said vertical wall openings whereby a surface of the cathode contained in each housing is exposed to air in said passage (32). A battery powered light source as claimed in claim 1, wherein the metal anode (36) is a plate having one or more slots. A battery powered light source as claimed in either one of claims 1 or 2, wherein the anode (36) and the cathode (34) of each pair are separated by a distance of about 1.5 mm to about 50 mm apart. A battery powered light source as claimed in any one of claims 1 to 3, wherein said anode (36) and cathode (34) cooperatively define a gap (G) opening directly downwardly into said cavity (22a). A battery powered light source as claimed in claim 1, wherein said support means comprises one or more platforms (38) which project from said interior side of the vertical wall (26) of the housing and form flat horizontal surfaces on which the anode (36) rests. A battery powered light source as claimed in any one of the preceding claims, wherein said common air passage (32) is open-ended and laterally confined between passage-defining wall portions (26a) of adjacent housings, said portions having said openings (28) through which said cathode surfaces are exposed to air in said passage. A battery powered light source as claimed in any one of the preceding claims, wherein socket (14) contains an electric light bulb.

Inventors: HAMLEN, ROBERT P., KOBASZ, WILLIAM, ROSE, MICHAEL V., ZOLTNER, THOMAS J.
Applicants: ALCAN INTERNATIONAL LIMITED
Application year: 1987
Main classification: H01M12
IPC codes: H01M12, H01M2