U.S. patent application number 10/429910 was filed with the patent office on 2004-01-08 for appliance with refuelable and rechargeable metal-air fuel cell battery power supply unit integrated therein.
Invention is credited to Faris, Sadeg M., Tsai, Tsepin.
Application Number | 20040005488 10/429910 |
Document ID | / |
Family ID | 24794115 |
Filed Date | 2004-01-08 |
United States Patent
Application |
20040005488 |
Kind Code |
A1 |
Faris, Sadeg M. ; et
al. |
January 8, 2004 |
Appliance with refuelable and rechargeable metal-air fuel cell
battery power supply unit integrated therein
Abstract
A device/system having an integrated refuelable and rechargable
metal-air FCB based power supply unit for generating and providing
electrical power to at least one electrical-energy-consuming load
device disposed therein. An external power source is used to
recharge the metal-air FCB subsystems embodied therein. A control
subsystem automatically transitions between discharging mode
(wherein at least one metal-air FCB subsystem supplies electrical
power to the electrical power-consuming load device) and a
recharging mode (wherein the external power source is electrically
coupled to at least one metal-air FCB subsystem to thereby recharge
the metal-air FCB subsystem(s). The metal-air FCB subsystem(s) are
refueled by manually loading and unloading metal-fuel from the
metal-air FCB subsystem(s). Preferably, electrical power provided
to the at least one electrical power-consuming load device is
supplied solely by electrical power generated by discharging
metal-fuel in the metal-air fuel cell battery subsystem(s). In
addition, the metal-air FCB subsystem(s) preferably has a modular
architecture that enable flexible and user-friendly operations in
loading of metal-fuel, unloading of consumed metal-fuel,
replacement of the ionic-conducting medium, and replacement of the
cathode.
Inventors: |
Faris, Sadeg M.;
(Pleasantville, NY) ; Tsai, Tsepin; (Chappaqua,
NY) |
Correspondence
Address: |
REVEO, INC.
85 Executive Boulevard
Elmsford
NY
10523
US
|
Family ID: |
24794115 |
Appl. No.: |
10/429910 |
Filed: |
May 5, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10429910 |
May 5, 2003 |
|
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09695697 |
Oct 24, 2000 |
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6558829 |
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Current U.S.
Class: |
429/404 ;
429/403; 429/418; 429/515 |
Current CPC
Class: |
H01M 12/08 20130101;
Y02E 60/10 20130101; H01M 10/42 20130101; Y02E 60/50 20130101; H01M
8/04 20130101; H01M 2004/024 20130101; H01M 6/42 20130101; H01M
12/06 20130101 |
Class at
Publication: |
429/23 ;
429/27 |
International
Class: |
H01M 008/04 |
Claims
What is claimed is:
1. An appliance for use with an external power source, the
appliance comprising: a system housing with at least one
electrical-energy-consumin- g load device disposed therein; a
refuelable and rechargable power supply unit integrated into the
system housing, the power supply unit comprising: a metal-air fuel
cell battery subsystem comprising at least one metal-air fuel cell
capable of generating and storing electrical power, wherein
consumed metal-fuel is unloaded from and metal fuel loaded into the
metal-air fuel cell battery subsystem to thereby refuel the
metal-air fuel cell battery subsystem; and a controller that
enables electrical connection from the metal-air fuel cell battery
subsystem to the electrical power-consuming load device in a
discharging mode to thereby supply electrical power to the
electrical power-consuming load device, and that enables electrical
connection from the external power source to the metal-air fuel
cell battery subsystem in a recharging mode to thereby recharge the
metal-air fuel cell battery subsystem.
2. The appliance of claim 1, wherein electrical power provided to
the electrical power-consuming load device is supplied solely by
the metal-air fuel cell battery subsystem.
3. The appliance of claim 2, wherein electrical power provided to
the electrical power-consuming load device is supplied solely by
electrical power generated by the metal-air fuel cell battery
subsystem operating in discharging mode.
4. The appliance of claim 1, further comprising an input power bus
and output power bus both coupled to the metal-air fuel cell
battery subsystem, wherein the input power bus provides an
electrical connection from the external power source to the
metal-fuel cell battery subsystem in the recharging mode to thereby
recharge the metal-air fuel cell battery system, and wherein the
output power bus provides an electrical connection from the
metal-fuel cell battery subsystem to said electrical
power-consuming load device in the discharging mode to thereby
provide electrical power to the electrical power-consuming load
device.
5. The appliance of claim 4, wherein the metal-air fuel cell
battery subsystem comprises a network of metal-air fuel cell
modules each comprising a plurality of metal-air fuel cells,
wherein the network of metal-air fuel cell modules includes a first
set of modules distinct from a second set of modules; and wherein
said controller operates the first set of modules in discharging
mode (to thereby supply electrical power from the first set of
modules to said electrical power-consuming load device via the
output power bus) concurrent with operation of the second set of
modules in recharging mode (to thereby recharge the second set of
modules with electrical power supplied from the external power
source via the input power bus).
6. The appliance of claim 4, wherein the metal-air fuel cell
battery subsystem comprises a plurality of metal-air fuel cells
including a first set of metal-air fuel cells distinct from a
second set of fuel cells; and said controller operates the first
set of fuel cells in discharging mode (to thereby supply electrical
power from the first set of fuel cells to said electrical
power-consuming load device via the output power bus) concurrent
with operation of the second set of fuel cells in recharging mode
(to thereby recharge the second set of fuel cells with electrical
power supplied from the external power source via the input power
bus).
7. The appliance of claim 1, wherein the system housing and modular
housing include recesses into which metal-fuel is manually loaded
into the metal-air fuel cell battery subsystem and from which
consumed metal-fuel is manually unloaded from the metal-air fuel
cell battery subsystem.
8. The appliance of claim 7, wherein the metal-fuel is disposed on
card structure that is manually loaded into and unloaded from the
recesses.
9. The appliance of claim 8, wherein the card structure comprises a
plurality of distinct metal-fuel elements integrated therein.
10. The appliance of claim 7, wherein the metal-fuel is disposed in
a cartridge that is that is manually loaded into and unloaded from
the recesses.
11. The appliance of claim 10, wherein the cartridge holds
metal-fuel tape.
12. The appliance of claim 10, wherein the cartridge holds sheets
of metal-fuel.
13. The appliance of claim 10, wherein the cartridge stores a paste
including anode material particles suspended in a liquid
ionically-conducting medium.
14. The appliance of claim 1, wherein the appliance comprises a
computer processing apparatus.
15. The appliance of claim 1, wherein the appliance comprises a
portable electronic device.
16. The appliance of claim 15, wherein the portable electronic
device is one of the following: radio, disc player, other music
playing devices, camcorder, other video playing/recording devices,
telephone, PDA, other communication devices.
17. The appliance of claim 1, where the appliance comprises one of
the following: television, audio equipment, washing machine,
refrigerator, freezer, oven, stove, furnace, air conditioner.
18. The appliance of claim 1, wherein the appliance comprises an
electrically-powered tool.
19. The appliance of claim 1, wherein the appliance comprises an
electrical-energy consuming device.
20. The appliance of claim 1, wherein the external power source
comprises a public electric utility grid.
21. The appliance of claim 1, wherein the external power source
derives energy from a public utility grid.
22. The appliance of claim 1, wherein the external power source
comprises a wind-driven power generator.
23. The appliance of claim 1, wherein the external power source
comprises a generator that derives energy from solar energy.
24. The appliance of claim 4, further comprising an switching
network, coupled to the input power bus, the output power bus, and
the power terminals of a plurality of metal-air fuel cell battery
subsystems that operates, in response to control signals from said
controller, to: selectively couple the input power bus to the power
terminals of one or more of the plurality of metal-air fuel cell
battery subsystems; to selectively couple the output power bus to
the power terminals of one or more of the plurality of metal-air
fuel cell battery subsystems; and to selectively couple together
the power terminals of two or more of the metal-air fuel cell
battery subsystems.
25. A method for operating an appliance comprising a system housing
with at least one electrical-energy-consuming load device disposed
therein, the method comprising the steps of: providing a power
supply unit integrated into the system housing, the power supply
unit having a metal-air fuel cell battery subsystem disposed within
a modular housing, the metal-air fuel cell battery subsystem
comprising at least one metal-air fuel cell capable of generating
and storing electrical power, and wherein consumed metal-fuel is
unloaded from and metal-fuel is loaded into the metal-air fuel cell
battery subsystem to thereby refuel the metal-air fuel cell battery
subsystem; and providing a control subsystem that operates in a
discharging mode to enable electrical connection from the
metal-fuel cell battery subsystem to the electrical power-consuming
load device to thereby supply electrical power to the electrical
power-consuming load device, and that operates in a recharging mode
to enable electrical connection from an external power source to
the metal-fuel cell battery to thereby recharge the metal-air fuel
cell battery subsystem.
26. The method of claim 25, wherein electrical power provided to
the electrical power-consuming load device is supplied solely by
electrical power supplied by the metal-air fuel cell battery
subsystem.
27. The method of claim 26, wherein electrical power provided to
the electrical power-consuming load device is supplied solely by
electrical power generated by discharging the metal-air fuel cell
battery subsystem.
28. The method of claim 25, further comprising an input power bus
and output power bus both coupled to the metal-air fuel cell
battery subsystem, wherein the input power bus provides an
electrical connection from the external power source to the
metal-fuel cell battery subsystem in the recharging mode to thereby
recharge the metal-air fuel cell battery system, and wherein the
output power bus provides an electrical connection from the
metal-fuel cell battery subsystem to said electrical
power-consuming load device in the discharging mode to thereby
provide electrical power to the electrical power-consuming load
device.
29. The method of claim 28, wherein the metal-air fuel cell battery
subsystem comprises a network of metal-air fuel cell modules each
comprising a plurality of metal-air fuel cells, wherein the network
of metal-air fuel cell modules includes a first set of modules
distinct from a second set of modules; and wherein said controller
operates the first set of modules in discharging mode (to thereby
supply electrical power from the first set of modules to said
electrical power-consuming load device via the output power bus)
concurrent with operation of the second set of modules in
recharging mode (to thereby recharge the second set of modules with
electrical power supplied from the external power source via the
input power bus).
30. The method of claim 28, wherein the metal-air fuel cell battery
subsystem comprises a plurality of metal-air fuel cells including a
first set of metal-air fuel cells distinct from a second set of
fuel cells; and said controller operates the first set of fuel
cells in discharging mode (to thereby supply electrical power from
the first set of fuel cells to said electrical power-consuming load
device via the output power bus) concurrent with operation of the
second set of fuel cells in recharging mode (to thereby recharge
the second set of fuel cells with electrical power supplied from
the external power source via the input power bus).
31. The method of claim 25, wherein said system housing and modular
housing include recesses into which metal-fuel is manually loaded
into the metal-air fuel cell battery subsystem and from which
metal-fuel is manually unloaded from the metal-air fuel cell
battery subsystem.
32. The method of claim 31, wherein the metal-fuel is disposed on
card structure that is manually loaded into and unloaded from the
recesses.
33. The method of claim 32, wherein the card structure comprises a
plurality of distinct metal-fuel elements integrated therein.
34. The method of claim 31, wherein the metal-fuel is disposed in a
cartridge that is that is manually loaded into and unloaded from
the recesses.
35. The method of claim 34, wherein the cartridge holds metal-fuel
tape.
36. The method of claim 34, wherein the cartridge holds sheets of
metal-fuel.
37. The method of claim 34, wherein the cartridge stores a paste
including anode material particles suspended in a liquid
ionically-conducting medium.
38. The method of claim 25, wherein the appliance comprises a
computer processing apparatus.
39. The method of claim 25, wherein the appliance comprises a
portable electronic device.
40. The method of claim 39, wherein the portable electronic device
is one of the following: radio, disc player, other music playing
devices, camcorder, other video playing/recording devices,
telephone, PDA, other communication devices.
41. The method of claim 25, where the appliance comprises one of
the following: television, audio equipment, washing machine,
refrigerator, freezer, oven, stove, furnace, air conditioner.
42. The method of claim 25, wherein the appliance comprises an
electrically-powered tool.
43. The method of claim 25, wherein the appliance comprises an
electrical-energy consuming device.
44. The method of claim 25, wherein the external power source
comprises a public electric utility grid.
45. The method of claim 25, wherein the external power source
derives energy from a public utility grid.
46. The method of claim 25, wherein the external power source
comprises a wind-driven power generator.
47. The method of claim 25, wherein the external power source
comprises a generator that derives energy from solar energy.
48. The method of claim 28, further comprising the step of:
operating a switching network coupled to the input power bus, the
output power bus, and the power terminals of a plurality of
metal-air fuel cell battery subsystems, in response to control
signals from said controller, to: selectively couple the input
power bus to the power terminals of one or more of the plurality of
metal-air fuel cell battery subsystems; to selectively couple the
output power bus to the power terminals of one or more of the
plurality of metal-air fuel cell battery subsystems; and to
selectively couple together the power terminals of two or more of
the metal-air fuel cell battery subsystems.
Description
RELATED CASES
[0001] This Application is related to U.S. patent application Ser.
No. 09/695,698, assigned to Reveo, Inc. and entitled "Refuelable
And Rechargeable Metal-Air Fuel Cell Battery Power Supply Unit For
Integration Into An Appliance., and to U.S. patent application Ser.
No. 09/695,699, assigned to Reveo, Inc. and entitled "POWER
GENERATION AND DISTRIBUTION SYSTEM/NETWORK HAVING INTERRUPTABLE
POWER SOURCE AND REFUELABLE AND RECHARGEABLE METAL-AIR FUEL CELL
BATTERY SUBSYSTEM", filed concurrently herewith.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to improved methods and
systems for electrochemically producing electrical power using
metal-air fuel cell battery (FCB) technology.
[0004] 2. Description of the Related Art
[0005] An ever-expanding range of electrical systems and devices
are vital to the normal continuation of daily life for individuals
and businesses in today's society. Such systems and devices include
portable devices (radio/tape/CD/DVD systems, PDA devices, notebook
computers, cell phones, video equipment, calculators, fans, lawn
mowers, screw drivers, drills, saws), appliances (refrigerators,
freezers, air conditioners, toasters, televisions, audio equipment,
washing machines, ovens, stoves, and furnaces), transportation
devices (power passenger vehicles, buses, golf carts, motorcycles,
boats, etc), computer processing and telecommunication equipment
(servers, desktop computers, communication routing and switching
systems) and the electrical infrastructure in homes, schools,
factories, and office buildings.
[0006] Traditionally, the utility-maintained power grid provides
power to these vital systems and devices. However, the reliability
of this power grid is fragile and can be compromised by
unpredictable severe weather (snow/ice storms, earthquakes,
tornadoes, hurricanes), system failure (excessive demand, lack of
supply of natural gas to generation systems) and/or human
error.
[0007] For example, during the week of Jan. 5, 1998, a severe
freezing-rain storm hit Canada and the northeastern United States
as warm moist air from the Gulf of Mexico encountered cold Arctic
air in three Canadian provinces and in northern New York, Vermont,
New Hampshire, and Maine. Ice accumulation on trees and overhead
lines caused hundreds of millions of dollars of damage in both the
United States and Canada and left hundreds of thousands of people
without power for periods ranging from a few hours to more than
three weeks. In the United States the President declared disasters
in five New York counties, six Vermont counties, and all New
Hampshire and Maine counties except along the coast.
[0008] In another example, during the unusually hot summer of 1988,
the power infrastructure of Auckland, New Zealand unpredictably
could not handle the stress caused by the extreme demand, and the
aging underground transmission cables that were vital to feeding
the city with electricity failed in succession. Full service was
not restored for five to eight weeks.
[0009] Thus, previous failures of the power grid have shown that
the disruptions caused by such failures can be massive, especially
if the failures are prolonged.
[0010] Alternate forms of power generation systems have been
proposed as the primary source of power (and, possibly, the
auxiliary source of power) for the broad range of electrical
systems and devices used by individuals and businesses in today's
society. These alternate forms of power generation systems include,
for example, solar-powered generation systems, wind-powered
generation systems, and hydroelectric generation systems. However,
the reliability of many of these alternate power generation systems
is also fragile. For example, the supply of power from
solar-powered generation systems/wind-powered generation
systems/hydroelectric generation systems can be unpredictably
interrupted for prolonged periods of time due to weather conditions
(lack of sunlight/lack of wind/severe drought conditions).
[0011] In such systems, interruptions can lead to unwanted
disruptions, especially if the interruptions are prolonged.
[0012] Traditionally, auxiliary power generation devices using
batteries, gasoline engines or diesel engines are used to provide
backup power in the event that such a prolonged interruption occurs
in the utility-maintained power grid (or other primary power
source). These systems too have serious limitations.
[0013] More specifically, auxiliary power generation devices that
use conventional battery technology (lead acid, nickel-cadmium, or
nickel-metal hydrides) have limited operation time, long recharge
time, and low energy density; thus making such devices impractical
for many applications. Moreover, replacement of such batteries is
costly and raises numerous environmental hazards (that typically
are dealt with using special encapsulation containers and careful
disposal).
[0014] Similarly, auxiliary power generation devices that use
combustible fuel (such as gasoline and diesel engine generators)
are costly, heavy, loud, emit noxious gases and fumes; thus making
such devices impractical for many applications. Moreover, such
devices raise numerous environmental and safety hazards related to
the transportation and use of the combustible fuels used
therein.
[0015] Thus, there is a great need in the art to provide a reliable
(i.e., not susceptible to prolonged interruption), efficient, user
friendly, environment friendly and safe source of power for the
broad range of electrical systems and devices that are vital to
individuals and businesses in today's society.
OBJECTS AND SUMMARY OF THE INVENTION
[0016] Accordingly, a prime object of the present invention is to
substitute the traditional power supply units and methodologies
(typically, one or more switching power regulators) integrated in
an electrical system or device with an integrated power supply unit
comprising one or more rechargeable and refuelable metal-air
FCB-based subsystems. This solution is, energy efficient,
environmentally-friendly, and reliable, thus enabling consumers to
use the system/device without the risk and limitations of prolonged
interruption. Moreover, the solution is cost-effect because it
eliminates the need for auxiliary power generation systems by
integrating the rechargeable and refuelable metal-air FCB-based
subsystem into the system/device. The electrical system or device
may be a computer processing apparatus, a portable electronic
device (such as radio, disc player, other music playing devices,
camcorder, other video playing/recording devices, telephone, PDA,
other communication devices), an appliance (such as television,
audio equipment, washing machine, refrigerator, freezer, oven,
stove, furnace, air conditioner) or an electrically-powered
tool.
[0017] Another object of the present invention is to provide
improved systems, apparatus and methods for electrochemically
providing electrical power to electrical devices and systems while
overcoming all of the limitations of known battery and conventional
power generating technologies.
[0018] Another object of the present invention is to provide an
appliance with a refuelable and rechargable power supply unit
integrated therein.
[0019] Another object of the present invention is to provide an
appliance with a system housing and a refuelable and rechargable
metal-air based power supply unit integrated into the system
housing.
[0020] Another object of the present invention is to provide an
appliance and integrated refuelable and rechargable metal-air FCB
based power supply unit, wherein the power supply unit comprises a
control subsystem that automatically transitions between
discharging mode and recharging mode for the metal-air FCB
subsystems therein.
[0021] Another object of the present invention is to provide an
appliance and integrated refuelable and rechargable metal-air FCB
based power supply unit, wherein supply of electrical power to the
electrical power-consuming load device in the appliance is supplied
solely by a metal-air fuel cell battery subsystem.
[0022] Another object of the present invention is to provide an
appliance and integrated refuelable and rechargable metal-air FCB
based power supply unit, wherein electrical power provided to the
electrical power-consuming load device in the appliance is supplied
solely by electrical power generated by discharging metal-fuel in a
metal-air fuel cell battery subsystem.
[0023] Another object of the present invention is to provide an
appliance and integrated refuelable and rechargable metal-air FCB
based power supply unit, wherein an input power bus and output
power bus are both coupled to a metal-air fuel cell battery
subsystem, the input power bus providing an electrical connection
from an external power source to the metal-fuel cell battery
subsystem in the recharging mode to thereby recharge the metal-air
fuel cell battery system, and the output power bus providing an
electrical connection from the metal-fuel cell battery subsystem to
the electrical power-consuming load device(s) in the appliance in
the discharging mode to thereby provide electrical power to the
electrical power-consuming load device(s). The metal-air fuel cell
battery subsystem may comprise a network of metal-air fuel cell
modules each comprising one or more metal-air fuel cells.
[0024] Another object of the present invention is to provide an
appliance and integrated refuelable and rechargable metal-air FCB
based power supply unit, wherein the metal-air fuel cell battery
subsystem comprises a network of metal-air fuel cell modules each
comprising one or more metal-air fuel cells, and a switching
network, under control of a control subsystem, that selectively
couples the input power bus and output power bus to the power
terminals of the network (and that selectively couples together the
power terminals of the network).
[0025] Another object of the present invention is to provide a
metal-air FCB system that enables efficient, automated, flexible
and user-friendly refueling operations in such metal-air FCB
systems, and the replacement of cathode elements and ionically
conducting medium by consumers.
[0026] Another object of the present invention is to provide a
metal-air fuel cell battery (FCB) system, wherein metal-fuel is
provided within a modular housing that is manually
insertable/removable within an aperture of the metal-air FCB
system, to thereby enable efficient, flexible and user-friendly
refueling operations of such metal-air FCB systems by
consumers.
[0027] Another object of the present invention is to provide a
metal-air fuel cell battery (FCB) system, wherein cathode
structures are provided within a modular housing that is manually
insertable/removable within an aperture of the metal-air FCB
system, to thereby enable efficient, flexible and user-friendly
replacement of cathode elements in such metal-air FCB systems by
consumers.
[0028] Another object of the present invention is to provide a
metal-air FCB system, wherein metal-fuel cards are manually
insertable/removable within an aperture of the metal-air FCB
system, to thereby enable efficient, flexible and user-friendly
replacement of metal-fuel cards in such metal-air FCB systems by
consumers.
[0029] Another object of the present invention is to provide a
metal-air fuel cell battery (FCB) system, wherein a card structure
comprising cathode elements is manually insertable/removable within
an aperture of the metal-air FCB system, to thereby provide
efficient, flexible and user-friendly operations that are suitable
for consumers in replacing cathode elements of such metal-air FCB
systems.
[0030] Another object of the invention is to provide a metal-air
FCB system wherein metal-fuel tape is housed in a cassette-type
cartridge that is manually insertable/removable within an aperture
of a metal-air FCB system, to thereby provide efficient, flexible
and user-friendly operations that are suitable for consumers in
replacing the metal-fuel tape of such metal-air FCB systems.
[0031] Another object of the invention is to provide a metal-air
FCB system wherein metal fuel paste is housed in a modular
container that is manually insertable/removable within an aperture
of a metal-air FCB system, to thereby enable efficient, flexible
and user-friendly replacement of the metal-fuel paste in such
metal-air FCB systems by consumers.
[0032] Another object of the present invention is to provide a
metal-air fuel cell battery (FCB) system, wherein a modular
structure including a cathode element (that interfaces to a
metal-fuel paste container) is manually insertable/removable within
an aperture of the metal-air FCB system, to thereby enable
efficient, flexible and user-friendly replacement of the cathode
elements in such metal-air FCB systems by consumers.
[0033] These and other objects of the present invention will become
apparent hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] For a more complete understanding of the Objects of the
Present Invention, the following detailed Description of the
Illustrative Embodiments Of the Present Invention should be read in
conjunction with the accompanying Drawings, wherein:
[0035] FIG. 1A is a schematic representation of a generalized
embodiment of a device/system have an integrated power supply unit
utilizing refuelable and rechargeable metal-air FCB technology,
wherein a network of metal-air FCB subsystems are operably
connected to a power bus structure and controlled by a control
subsystem.
[0036] FIG. 1B is a schematic representation of a generalized
embodiment of a power generation and distribution system using a
refuelable and rechargeable metal-air FCB based power supply unit,
wherein a network of metal-air FCB subsystems are operably
connected to a power bus structure and controlled by a control
subsystem.
[0037] FIG. 1C is a schematic representation of a generalized
embodiment of the refuelable and rechargable metal-air FCB based
power supply unit of the present invention, wherein a network of
metal-air FCB subsystems are operably connected to a power bus
structure and controlled by a control subsystem in operable
association with a metal-fuel management subsystem.
[0038] FIG. 2 is a schematic representation of the modes of
operation of the refuelable and rechargable metal-air FCB based
power supply unit of FIGS. 1A-1C as controlled by the control
subsystem.
[0039] FIG. 3 is an exploded perspective view of the first
illustrative embodiment of a metal-air FCB based power supply unit
of FIGS. 1A-1C according to the present invention, wherein the
upper housing portion is detached from the lower housing portion to
reveal that the four-element cathode structure (i.e., submodule) is
releasably inserted into a recess formed in the lower housing
portion, and wherein a four-element metal fuel card is slidably
inserted into a second recess between the upper housing portion and
the four-element cathode structure.
[0040] FIG. 4 is a schematic block diagram of a second illustrative
embodiment of a metal-air FCB based power supply unit of FIGS.
1A-1C according to the present invention, wherein metal-fuel tape
housed in a cassette-type module is manually inserted into a port
in the subsystem for transport to a Metal-Fuel Tape Discharging
Subsystem and a Metal-Fuel Recharging Subsystem.
[0041] FIG. 5 is a schematic representation of an exemplary
Fuel-Tape Discharging Subsystem of the second illustrative
embodiment of FIG. 4 according to the present invention, wherein
metal-fuel tape is passed over a rotating cylindrical cathode
structure.
[0042] FIG. 6 is a perspective view of a third illustrative
embodiment of a metal-air FCB based power supply unit of FIGS.
1A-1C according to the present invention, wherein a container
holding metal-fuel paste is manually insertable into a recess in
the housing of the system; the paste is transported to pass by
apertures in the container that are spatially arranged with respect
to the anode-contacting element and cathode structure of a
discharge head assembly, to thereby expose the paste to the
discharge head assembly for discharging operations; the cathode
structure and anode-contacting element of the discharging head
assembly is preferably releasably insertable into a second recess
in the housing to provide for efficient replacement of these
elements.
[0043] FIG. 7 is an exploded perspective view of the third
illustrative embodiment of FIG. 6 according to the present
invention, wherein the upper housing portion is detached from the
lower housing portion to reveal that the paste container is
slidably inserted into a first-recess formed in the housing, and
the discharge head assembly (comprising an anode-contacting element
and cathode structure) slidably inserted into a second recess
formed in the housing.
[0044] FIG. 8 is a perspective view of a computer processing
apparatus (such as a server that provides data processing
capabilities to an enterprise) having an integrated refuelable and
rechargable metal-air FCB based power supply unit that generates
and supplies electrical power to the devices of the apparatus,
wherein at least one auxiliary power source is provided for
recharging metal-fuel within the FCB subsystems thereof, and
wherein the metal-air FCB based power supply unit preferably
includes at least one recess for slidably inserting and removing
metal-fuel used therein and for slidably inserting and removing
cathode structures used therein.
[0045] FIG. 9 is a perspective view of a portable electronics
device (such as a wireless communication device) having an
integrated refuelable and rechargable metal-air FCB based power
supply unit that generates and supplies electrical power to the
devices disposed therein, wherein the metal-air FCB based power
supply unit includes at least one auxiliary power source for
recharging metal-fuel within the FCB subsystems thereof, and
wherein the metal-air FCB based power supply unit preferably
includes a recess for slidably inserting and removing metal-fuel
used therein.
[0046] FIG. 10 is a perspective view of an electrical power
generation system of the present invention including a refuelable
and rechargable metal-air FCB based power supply unit that
generates and supplies electrical power to one or more electrical
power-consuming load devices, wherein an interruptible auxiliary
power source(s) is provided for recharging metal-fuel within the
FCB subsystems thereof, and wherein the metal-air FCB based power
supply unit preferably includes at least one recess for slidably
inserting and removing metal-fuel used therein and for slidably
inserting and removing cathode structures used therein.
[0047] FIG. 11 is a perspective view of a building, wherein the
electrical power distribution system of the present invention is
interfaced to the power distribution panel of the building; the
electrical power distribution system includes a refuelable and
rechargable metal-air FCB based power supply unit that generates
and supplies electrical power to the electrical power-consuming
load devices of the building, wherein an interruptible auxiliary
power source(s) is provided for recharging metal-fuel within the
metal-air FCB subsystems thereof, and wherein the metal-air FCB
based power supply unit preferably includes at least one recess for
slidably inserting and removing metal-fuel used therein and for
slidably inserting and removing cathode structures used
therein.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS OF THE PRESENT
INVENTION
[0048] Referring now to the figures in the accompanying Drawings,
the best modes for carrying out the present invention will now be
described in great technical detail, wherein like elements are
indicated by like reference numbers.
[0049] In general, the metal-air FCB-based systems according to the
present invention load metal-fuel material, in the form cards,
sheets, tape, paste and the like, to a Metal-Fuel Discharge
Subsystem, or a Metal-Fuel Recharge Subsystem, depending on the
mode of the system. When loaded into the Metal-Fuel Discharge
Subsystem, the metal-fuel is discharged by (i.e. electro-chemically
reaction with) one or more discharging heads in order produce
electrical power across an electrical power-consuming load
connected to the subsystem while H.sub.2O and O.sub.2 are consumed
at the cathode-electrolyte interface during the electrochemical
reaction. When transported to or through the Metal-Fuel Recharging
Subsystem, discharged metal-fuel is recharged by one or more
recharging heads in order to convert the oxidized metal-fuel
material into its source metal material suitable for reuse in power
discharging operations, while O.sub.2 is released at the
cathode-electrolyte interface during the electrochemical reaction.
The electrochemistry upon which such discharging and recharging
operations are based is described in Applicant's co-pending U.S.
application Ser. No. 08/944,507, U.S. Pat. No. 5,250,370, and other
applied science publications well known in the art. These
principles will be briefly summarized below. Also note that the
Metal-Fuel Discharge Subsystem and Metal-Fuel Recharge Subsystem
may utilize common components and handling systems, as is well
known in the art.
[0050] During discharging operations, the Metal-Fuel Discharge
Subsystem brings metal-fuel (such as zinc, aluminum, magnesium or
beryllium), which is employed as an electrically-conductive anode,
into "ionic-contact" with an electrically-conductive
oxygen-pervious cathode structure, by way of an
ionically-conducting medium. In the preferred embodiment of the
present invention, the ionically-conducting medium is integrated to
the metal-fuel anode structure. The ionically-conducting medium may
be an ionically-conducting polymer, an electrolyte gel, or a liquid
such as KOH or NaOH. When the cathode and anode structure are
brought into ionic contact, a characteristic open-cell voltage is
automatically generated. The value of this open-cell voltage is
based on the difference in electro-chemical potential of the anode
and cathode materials. When an electrical power-consuming load is
connected across the cathode and anode structures of the metal-air
FCB cell, so constructed, the Metal-Air Discharge Subsystem
delivers electrical power to the electrical power-consuming load,
as oxygen O.sub.2 from the ambient environment is consumed and
metal-fuel anode material oxidizes. In the case of a zinc-air FCB
system or device, the zinc-oxide (ZnO) is formed on the zinc anode
structure during the discharging cycle, while oxygen is consumed at
within the region between the adjacent surfaces of the cathode
structure and electrolytic medium (hereinafter referred to as the
"cathode-electrolyte interface" for purposes of convenience).
[0051] During recharging operations, the Metal-Fuel Recharging
Subsystem brings the consumed anode material (i.e., oxidized metal)
into "ionic-contact" with a cathode structure, by way of the
ionically-conducting medium, and applies a power source (e.g. more
than 2 volts for zinc-air systems) across the cathode structure and
consumed anode material. There while, the Metal-Fuel Recharging
Subsystem controls the electrical current flowing between the
cathode and consumed anode structures, in order to reverse the
electro-chemical reaction which occurred during discharging
operations. In the case of the zinc-air FCB system or device, the
zinc-oxide (ZnO) formed on the zinc anode structure during the
discharging cycle is converted into (i.e. reduced back) into zinc,
while oxygen O.sub.2 is released at the cathode-electrolyte
interface to the ambient environment.
[0052] After a number of discharge/recharge cycles, a refueling
operation is required wherein the consumed anode material (e.g.,
oxidized metal) is replaced with "fresh" anode material to provide
a source of metal-fuel to the metal-air FCB system.
[0053] The cathode structure(s) of the metal-air FCB system also
has a limited lifetime. Generally, the cathode structure comprises
an oxygen-permeable mesh of inert conductor and a catalyst for
reducing oxygen that diffuses through the mesh into the system.
Typically, the operational lifetime of the cathode structure(s) of
the metal-air FCB system extends beyond that of a single metal-fuel
anode (e.g., 10 to 50 times the operational lifetime), and thus it
may be used repeatably after replacing the corresponding anode
element. When the operational lifetime of the cathode element ends,
it may be cost effective to replace the "spent" cathode element,
or, in the alternative, to discard the metal-air FCB subsystem (or
the entire FCB system) that contains the "spent" cathode
element.
[0054] Generalized Embodiments of the Present Invention
[0055] According to the present invention, the traditional power
supply unit (typically, one or more switching power regulators)
integrated in an electrical system or device is substituted with a
power supply unit comprising one or more rechargeable and
refuelable metal-air FCB-based subsystems. FIG. 1A illustrates the
architecture of a generalized embodiment of an exemplary device
according to the present invention. As shown, the device 900-1
includes housing 901 with one or more electrical-power consuming
load devices 751 (depicted as electrical power-consuming loads 751A
and 751B) disposed therein. A power supply unit 700-1 comprising
one or more modules integrally disposed in the housing 901 is
electrically coupled to the one or more electrical power-consuming
load devices 751. The one or more modules of the power supply unit
700-1 include at least one rechargeable and refuelable metal-air
FCB subsystem 708 (depicted in FIG. 1A as subsystems 708A,708B . .
. 708N). Each metal-air FCB subsystem 708 comprises at least one
metal-air fuel cell that operates in a discharging mode to provide
electrical power to the output power bus 706 for supply to the one
or more electrical power-consuming load devices 751 via output port
755, and operates in a recharging mode to apply electrical power
(received from one or more external electrical-power sources 753
via input port 757 and input power bus 714) across the cathode
structure and consumed anode material of the metal-air fuel cell,
thereby reversing the electro-chemical reaction which occurred
during discharging mode of operation.
[0056] As shown in FIG. IA, the power supply unit 700-1 of the
appliance device 900-1 preferably includes output regulation and
load sensing circuitry 709, electrically coupled between the output
power bus 706 and the one or more electrical power-consuming load
devices 751, that operates in the discharging mode to regulate the
electric DC power supplied on the output power bus 706 to thereby
control the output voltage levels (and, preferably the output
current levels) supplied to the one or more electrical
power-consuming load devices 751 of the appliance device 900-1,
such that the power output from port 755 is in a form suitable for
consumption by the one or more electrical power-consuming load
devices 751. The output regulation and load sensing circuitry 709
may convert the DC electric power provided thereto to AC electrical
power for output to the one or more electrical power-consuming load
devices 751 in the event that the electrical power-consuming loads
require such AC electrical power. In addition, the output
regulation and load sensing circuitry 709 preferably includes
circuitry for sensing real-time conditions (voltage levels or
current levels) of the supply of power to the one or more
electrical power-consuming load devices 751 and generating control
signals indicative of such conditions. Such power regulation and
sense circuitry may be realized using solid state circuitry well
known the power generation and control arts.
[0057] As shown in FIG. 1A, the power supply unit 700-1 of the
appliance device 900-1 preferably includes input regulation
circuitry 715, coupled to the one or more external electrical-power
sources 753 (for example, the utility managed and maintained grid)
via input port 757, that operates in recharge mode to regulate the
input voltage levels (and, preferably the input current levels)
supplied thereto from the power source 753 such that it has DC
signal characteristics suitable for use by the metal-air FCB
subsystem(s) 708 in the recharge mode. The DC power signals
generated by input regulation circuitry 715 in the recharge mode
are delivered to the metal-air FCB subsystem(s) 708 over the input
power bus 714. The input regulation circuitry 715 may convert the
AC electric power provided thereto to DC electrical power for
supply to the metal-air FCB subsystem(s) 708 in the event that the
external power source(s) 753 supply AC electrical power. Such power
regulation circuitry may be realized using solid state circuitry
well known the power generation and control arts.
[0058] As shown in FIG. 1A, the power supply unit 700-1 preferably
includes an I/O switching network 761, coupled to the input power
bus 714, the output power bus 706, and the power terminals of each
metal-air fuel cell battery subsystem 708, that operates, in
response to control signals from a control subsystem 711 (e.g.,
programmed controller) supplied via signal path 737, to:
selectively couple the input power bus 714 to the power terminals
of one or more metal-air fuel cell battery subsystems 708 coupled
thereto; to selectively couple the output power bus 714 to the
power terminals of one or more metal-air fuel cell battery
subsystems 708 coupled thereto; and to selectively couple together
the power terminals of two or more of the metal-air fuel cell
battery subsystems 708 coupled thereto.
[0059] In general, the control subsystem 711 selectively activates
any one of the metal-air FCB subsystems 708 in the discharging mode
to contribute to power supplied to the one or more electrical
power-consuming load device(s) 751 via output port 755 by
controlling the switching network 761, via the signal path 737, to
couple the power terminals (preferably, the output power terminals)
of the selected metal-air FCB subsystems 708 to the output power
bus 706. In addition, the control subsystem 711 selectively
activates any one of the metal-air FCB subsystems 708 in the
recharging mode to use power supplied by external power source(s)
753 via input port 757 by controlling the switching network 761,
via the signal path 737, to couple the power terminals (preferably,
the input power terminals) of the selected metal-air FCB subsystems
708 to the input power bus 714. In addition, the control subsystem
711 preferably controls the switching network (via signal path 737)
to selectively couple together the power terminals of two or more
of the metal-air fuel cell battery subsystems 708 coupled thereto
to thereby selectively carry out multiple discharge schemes (some
of which combine the power output of the FCB subsystems to provide
output with current levels and/or voltage levels that cannot be
provided by one of the FCB subsystems alone).
[0060] In addition, the control subsystem 711 preferably controls
operation of the metal-air FCB subsystem(s) 708 within the network
(e.g. by way of controlling discharging/recharging parameters
during discharging/recharging modes of operation, respectively, and
collecting metal-fuel and metal-oxide indicative data from the
particular metal-air FCB subsystems on a real-time basis). A
control bus structure 712 operably couples the control subsystem
711 to each metal-air FCB subsystem 708 (to enable the transfer of
metal-fuel indicative data from the FCB subsystems to the control
subsystem 711, and the transfer of control signals from the control
subsystem 711 to the metal-air FCB subsystem(s) 708.
[0061] As shown in FIG. 1A, the control subsystem 711 is operably
coupled to other elements of the system via signal paths that
enable the exchange of control data therebetween. More
specifically, the control subsystem 711 is operably coupled to the
output regulation and load sensing circuitry 709 via signal path
731, and to the input regulation circuitry 715 via signal path
733.
[0062] It should be noted, that in the preferred embodiment of the
present invention, the one or more electrical power-consuming load
devices 751 of device/system 900-1 are supplied power solely via
the discharging operation of the metal-air FCB based power supply
unit 700-1 coupled thereto via output port 755, and the external
power source 753 is used by the device/system solely has a power
source in recharging the metal-air FCB based power supply unit
700-1.
[0063] Advantageously, the device/system of FIG. IA and the
rechargeable and refuelable metal-air FCB based power supply unit
integrated therein provides improved efficiency and reliability
over prior art devices/systems. More specifically, in the event
that a prolonged interruption occurs in the power delivered by an
external power source, such devices/systems can be used without
prolonged interruption by refueling the metal-air FCB based power
supply unit integrated therein, if need be. Moreover, the
environmental and safety hazards, costs, unfriendly noises and
other limitations associated with the prior forms of auxiliary
power generation (based upon conventional battery technology and
combustible fuel) are avoided.
[0064] In another aspect of the present invention, an interruptible
power generation system can be transformed to become an
uninterruptible power generation system. FIG. 1B illustrates the
architecture of a generalized embodiment of an exemplary
uninterruptible power generation system according to the present
invention. As shown, the system 950 includes an interruptible power
source 953 coupled a power supply unit 700-2. The power supply unit
700-2 is electrically coupled to the one or more electrical
power-consuming load devices 751' (shown as 751A' and 751B') via an
output port 755', and includes at least one rechargeable and
refuelable metal-air FCB subsystem 708' (depicted in FIG. 1B as
subsystems 708A',708B' . . . 708N'). Each metal-air FCB subsystem
708' comprises at least one metal-air fuel cell that operates in a
discharging mode to provide electrical power to the output power
bus 706' for supply to the one or more electrical power-consuming
load devices 751' via output port 755', and operates in a
recharging mode to apply electrical power (received from the
interruptible electrical-power sources 753' via input port 757' and
input power bus 714') across the cathode structure and consumed
anode material of the metal-air fuel cell, thereby reversing the
electrochemical reaction which occurred during discharging mode of
operation. In addition, the power supply unit 700-2 preferably
includes elements similar to the elements of the power supply unit
700-1 of FIG. 1A as set forth above.
[0065] It should be noted, that in the preferred embodiment of the
present invention, the one or more electrical power-consuming load
devices 751 ' coupled to the uninterruptible power generation
system 950 via output port 755' are supplied power solely via the
discharging operation of the metal-air FCB based power supply unit
700-2, and that the interruptible power source 953 is used solely
as a power source in recharging the metal-air FCB based power
supply unit 700-2.
[0066] Advantageously, the power generation system of FIG. 1B (and
the rechargeable and refuelable metal-air FCB based power supply
unit integrated therein) provides improved efficiency and
flexibility over prior art power generation systems. More
specifically, in the event that a prolonged interruption occurs in
the power delivered by an interruptible power source, the power
generation system can be used without prolonged interruption by
refueling the metal-air FCB based power supply unit integrated
therein, if need be. Hereto, the environmental and safety hazards,
costs, unfriendly noises and other limitations associated with the
prior art forms of auxiliary power generation (based upon
conventional battery technology and combustible fuel) are
avoided.
[0067] In yet another aspect of the present invention, the
metal-air FCB subsystems 708 as described above preferably have a
modular architecture to enable flexible and user-friendly
operations in loading of metal-fuel, unloading of consumed
metal-fuel, replacement of the ionic-conducting medium, and
replacement of the cathode. More specifically, the metal-air FCB
subsystem 708 preferably includes at least one first-module that
houses the metal-fuel anode material and the consumed anode
material for one or more of the cathode structures of the metal-air
FCB subsystem 708. The first-module is manually insertable into a
first recess in the housing of the metal-air FCB subsystem 708 (and
in the device/system in which the metal-air FCB subsystem is
integrated), wherein it is used in discharge operations and/or
recharge operations. In addition, one or more cathode structures of
the metal-air FCB subsystem 708 are preferably disposed in at least
one second-module that is manually insertable into a second recess
in the housing of the metal-air FCB subsystem 708 (and in the
device/system in which the metal-air FCB subsystem is integrated),
wherein the cathode element(s) disposed therein is used in
discharge operations and/or recharge operations.
[0068] During discharge operations, the metal-fuel anode material
housed in the first module is brought into "ionic-contact" with a
cathode structure, by way of the ionically-conducting medium. When
the cathode and anode material are brought into ionic contact, a
characteristic open-cell voltage is automatically generated. The
value of this open-cell voltage is based on the difference in
electro-chemical potential of the anode and cathode materials. When
an electrical power-consuming load is connected across the cathode
and anode structures of the metal-air FCB cell, so constructed, the
metal-air FCB subsystem 708 delivers electrical power to the
electrical power-consuming load, as oxygen O.sub.2 from the ambient
environment is consumed and metal-fuel anode material oxidizes.
[0069] During recharge operations, consumed anode material (e.g.,
oxidized metal-fuel material) housed in the first-module is brought
into "ionic-contact" with a cathode structure, by way of the
ionically-conducting medium, and power is applied thereto.
Therewhile, electrical current flowing between the cathode and
anode structures reverses the electrochemical reaction which
occurred during discharging operations.
[0070] During refueling operations, the first-module (that houses
consumed anode material, e.g., oxidized metal) is manually removed,
a first-module housing "fresh" anode material is loaded into the
first recess, to thereby enable loading of metal-fuel. In this
refueling operation, the corresponding cathode structure(s) (which
is/are preferably disposed in the second-module when manually
inserting the second-module into the second recess as set forth
above) need not be replaced.
[0071] During cathode replacement operations, one or more cathode
structures of the metal-air FCB system 708 are manually removed and
replaced with fresh cathode structure(s). Preferably, the cathode
structures are disposed in the second-module, and replaced by
manually loading the second-module (wherein one or more fresh
cathode structures are disposed) into the second-recess of the
system. The refueling operations described above (which loads a
first-module housing fresh metal-fuel and, possibly, fresh
ionically-conducting medium into the first recess in the main
housing of the metal-FCB system) may be performed in conjunction
with such cathode replacement operations.
[0072] The ionic-conducting medium may be integrated to the
metal-fuel anode material and disposed in the first-module when
loaded into the first recess of the housing of the system. In such
systems, the refueling operations set forth above replace the
first-module to thereby load both fresh anode material and fresh
ionically-conducting medium into the first-recess in the housing of
the system.
[0073] Alternatively, the ionic-conducting medium may be integrated
to the cathode structure(s) of the metal-air FCB cells and disposed
in the second-module when loaded into the second recess of the
housing of the system. In such systems, the cathode replacement
operations set forth above replace the second-module to thereby
load both fresh cathode structure(s) and fresh ionically-conducting
medium into the second-recess in the housing of the system.
[0074] In another embodiment, the ionic-conducting medium may not
be integrated to the anode material and the cathode structure(s) of
the metal-air FCB cells. In such systems, ionically-conducting
medium replacement operations are performed to replace
ionically-conducting medium for one or more of the metal-air FCB
cells with fresh ionically-conducting medium. It should be noted
such replacement operations may be performed in conjunction with
the refueling operations and cathode replacement operations set
forth above.
[0075] Advantageously, such a modular architecture enables flexible
and user-friendly operations in loading of metal-fuel, unloading of
consumed metal-fuel, replacement of the ionic-conducting medium,
and replacement of the cathode structures in metal-air FCB
systems.
[0076] FIG. 1C illustrates the architecture of a generalized
embodiment of the power supply unit 700 of the present invention.
FIG. 2 depicts the modes of operation of this exemplary power
supply unit 700, which preferably include a discharging mode,
recharging mode, refuel mode, and replace mode as shown. The power
supply unit 700 transitions between these modes based upon
predetermined conditions (such as detection of a user-input event,
sensing that one or more electrical power-consuming loads coupled
to the system require electrical power, or sensing that elements of
the system require refueling, recharging, or replacement (e.g.,
because the available power from one or more cells drops below a
predetermined threshold power level, or because the elements have
been used for a predetermined operational lifetime). A more
detailed description of the elements of the system and the
operation of the system in each of these modes follows below.
[0077] As shown in FIG. 1C, the exemplary power supply unit 700
comprises at least one metal-air FCB subsystem 708 (depicted in
FIG. 1C as subsystems 708A,708B, 708C, 708D . . . 708N) that
operates in a discharging mode to provide DC electric power to the
output power bus 706, thereby supplying DC electrical power to an
output regulation and load sensing circuitry 709. In the
discharging mode, the output regulation and load sensing circuitry
709 regulates the electric DC power supplied on the output power
bus structure 706 to control the output voltage levels (and,
preferably the output current levels) supplied to the electrical
power-consuming load(s) (two electrical power-consuming loads shown
as 751A and 751B) coupled thereto via output port 755, such that
the power output from port 755 is in a form suitable for
consumption by the electrical power-consuming load(s) 751. The
output regulation and load sensing circuitry 709 may convert the DC
electric power provided thereto to AC electrical power for output
to the electrical power-consuming load(s) 751 in the event that the
electrical power-consuming loads require such AC electrical
power.
[0078] As shown in FIG. 1C, the output regulation and load sensing
circuitry 709 preferably includes circuitry for sensing real-time
conditions (voltage levels or current levels) of the supply of
power to the electrical power-consuming load(s) 751 and generating
control signals indicative of such conditions. Such power
regulation and sense circuitry may be realized using solid state
circuitry well known the power generation and control arts.
[0079] As shown in FIG. 1C, the power supply unit 700 includes
input regulation circuitry 715, coupled to one or more electric
power sources 753 via input port 757, that operates in recharge
mode to regulate the input voltage levels (and, preferably the
input current levels) supplied thereto from the power source 753
such that it has DC signal characteristics suitable for use by the
metal-air FCB subsystem(s) 708 in the recharge mode. The DC power
signals generated by input regulation circuitry 715 in the recharge
mode are delivered to the metal-air FCB system(s) 708 over the
input power bus 714. The input regulation circuitry 715 may convert
the AC electric power provided thereto to DC electrical power for
supply to the metal-air FCB subsystem(s) in the event that the
power source(s) supply AC electrical power. Such power regulation
circuitry may be realized using solid state circuitry well known
the power generation and control arts.
[0080] As shown in FIG. 1C, the power supply unit 700 preferably
includes conditioning and surge protection circuitry 721 coupled to
both the input port 757 and output port 755 to provide signal
filtering (for noise reduction) and surge protection functionality
with respect to the electrical power signals passing through both
the input port 757 and the output port 755. Such signal
conditioning and surge protection may be realized using solid state
circuitry well known the power generation and control art.
[0081] As shown in FIG. 1C, the power supply unit 700 includes a
control subsystem 711 (e.g. programmed controller) for controlling
the operation of the system. The control subsystem 711 preferably
interfaces to a user input module 727 for providing user input to
the control subsystem, and to a display device 729 for displaying
information relating to the status and operation of the system. The
user-input module 727 may comprise a touch pad, key pad, keyboard,
pointing device, touch input device, speech input system, or any
other means of providing user-input to the control subsystem 711.
The display device 729 may be a matrix display, one or more light
emitting diodes (LEDs), or any other means that communicates to the
user information relating to the status and operation of the
system. In addition, the control subsystem 711 preferably
interfaces to a communication input/output module 725 that provides
a communication link between the power generation system 700 and
other devices.
[0082] The control subsystem 711 controls operation of the
metal-air FCB subsystems within the network (e.g. by way of
controlling discharging/recharging parameters during
discharging/recharging modes of operation, respectively, and
collecting metal-fuel and metal-oxide indicative data from the
particular metal-air FCB subsystems on a real-time basis). A
control bus 712 operably couples the control subsystem 711 to each
metal-air FCB subsystem 708A through 708N (to enable the transfer
of metal-fuel indicative data from the FCB subsystems to the
control subsystem 711, and the transfer of control signals from the
control subsystem 711 to the FCB subsystems during discharge mode
operations).
[0083] Preferably, a metal-fuel management subsystem (e.g. a
relational database management system) 713 is operably coupled to
the control subsystem 711, for storing information representative
of the amount of metal-fuel (and metal-oxide) present along
metal-fuel zones in each FCB subsystem connected between bus
structures 706 and 712 in the system. The metal-fuel management
subsystem 713 may be operatively coupled to the control subsystem
711 over a communication link via the communication input/output
module 725.
[0084] As shown in FIG. 1C, the control subsystem 711 is operably
coupled to other elements of the system via signal paths that
enable the exchange of control data therebetween. More
specifically, the control subsystem 711 is operably coupled to the
output regulation and load sensing circuitry 709 via signal path
731, to input regulation circuitry 715 via signal path 733, and to
conditioning and surge protection circuitry via signal path
735.
[0085] In general, the control subsystem 711 selectively activates
any one of the metal-air FCB subsystems 708 in the discharging mode
to contribute to power supplied to the one or more electrical
power-consuming load device(s) 751 via output port 755 by
controlling the switching network 761 (via the signal path 737) to
couple the power terminals (preferably, the output power terminals)
of the selected metal-air FCB subsystems 708 to the output power
bus 706. In addition, the control subsystem 711 selectively
activates any one of the metal-air FCB subsystems 708 in the
recharging mode to use power supplied by external power source(s)
753 via input port 757 by controlling the switching network 761
(via the signal path 737) to couple the power terminals
(preferably, the input power terminals) of the selected metal-air
FCB subsystems 708 to the input power bus 714. In addition, the
control subsystem 711 preferably controls the switching network
(via signal path 737) to selectively couple together the power
terminals of two or more of the metal-air fuel cell battery
subsystems 708 coupled thereto to thereby selectively carry out
multiple discharge schemes (some of which combine the power output
of the FCB subsystems to provide output with current levels and/or
voltage levels that cannot be provided by one of the FCB subsystems
alone).
[0086] FIG. 2 illustrates the preferred modes of operation of the
power generation system 700 of FIGS. 1A-1C including a discharging
mode, recharging mode, refuel mode, and replace mode. Preferably,
the control operations performed in each mode and the transitions
between modes is performed by a control routine of instructions
stored in the memory of the control subsystem 711, and executed by
the controller of the control subsystem 711.
[0087] In the discharging mode, the control subsystem 711
selectively activates (via control bus 712) the Metal-Fuel
Discharge Subsystems of one or more of the metal-air FCB subsystems
708 to generate power and controls the switching network 761 (via
the signal path 737) to couple the power terminals (preferably, the
output power terminals) of the one or more activated metal-air FCB
subsystems 708 to the output power bus 706. In addition, the
control subsystem 711 preferably activates the output regulation
and load sensing circuitry 709 (via signal path 731) to provide
power on DC output power bus structure 706 to the electrical
power-consuming load(s) 751, which are coupled thereto via port
755. In addition, the control subsystem 711 preferably monitors
control signals generated by the load sensing circuitry 709 and
supplied thereto via signal path 731 to determine that the power
generated by the FCB subsystem(s) 708 and supplied to the
electrical power-consuming load(s) 751 is adequate. In the event
that this power is not adequate, the controller can adjust the
discharging operating parameters of the FCB system (or selectively
activate other FCB subsystems) to meet the required loading
conditions. In the alternative, the control subsystem may
transition to recharge mode and/or refuel mode if the FCB
subsystems of the power supply unit 700 cannot meet the required
demand.
[0088] In the recharging mode, the control subsystem 711
selectively activates (via control bus 712) the Metal-Fuel Recharge
Subsystems of one or more of the metal-air FCB subsystems 708 and
controls the switching network 761 (via the signal path 737) to
couple the power terminals (preferably, the input power terminals)
of the one or more activated metal-air FCB subsystems 708 to the
input power bus 714. In addition, the control subsystem 711
preferably activates the input regulation circuitry 715 (via signal
path 733) to provide power supplied thereto from power source(s)
753 via input port 757 to the input power bus 714, to thereby
recharge the selected metal-air FCB subsystems.
[0089] Moreover, in the event that that the system is not operating
in discharge mode (i.e., none of the metal-air FCB subsystems are
supplying power to the output bus 706), the control system 711 may
control the output regulation circuitry 709 (via signal path 731)
to isolate the output power bus 706 from the output port 755.
Similarly, in the event that that the system is not operating in
recharge mode (i.e., none of the metal-air FCB subsystems are
actively coupled to the input bus 714), the control system 711 may
control the input regulation circuitry 715 (via signal path 733)to
isolate the input power bus 714 from the input port 757.
[0090] During the refuel mode, the control subsystem 711 identifies
one or more first-modules disposed within the metal-air FCB
subsystems 708 that require replacement (preferably by monitoring
the information stored in the metal-fuel management subsystem 713
that is representative of the amount of metal-fuel and metal-oxide
disposed within the first-modules) and communicates with the user,
preferably via display 729, to provide an indication that the
identified first-modules require replacement. For each identified
first-module requiring replacement, the user manually removes the
first-module and loads a first-module housing "fresh" (i.e.,
(re)charged) anode material into the first recess in the housing.
After the replacement is complete (which may be detected manually
by user input, or automatically by sensing the amount of
metal-oxide disposed in the first-module inserted into the given
first-recess), the control subsystem 711 preferably updates the
information stored in the metal-fuel management subsystem 713
representative of the amount of metal-fuel disposed within the
first-modules. As set forth above, in the preferred embodiment of
the present invention, the first-module houses anode material
integral with ionically-conducting medium. In such systems, such
refuel mode operation replaces the first-module to enable loading
of both metal-fuel and "fresh" ionically-conducting medium. In
addition, in the refueling mode, the control subsystem 711 may
perform replace mode operations module as described below with
respect to cathode structures corresponding to the replaced
first-module.
[0091] In the replace mode, the control subsystem 711 identifies
one or more cathode structures that require replacement (preferably
by monitoring the information stored in the management subsystem
713 that is representative of the operational lifetime of the
particular cathode structure) and communicates with the user,
preferably via display 729, to provide an indication that the
identified cathode structure(s) require replacement. For each
identified cathode structure requiring replacement, the user
manually replaces the cathode structure. In the preferred
embodiment of the present invention, wherein the cathode structure
is disposed in a second-module that is manually loadable/unloadable
from a second-recess in the housing of the system, the user
manually removes the second-module from the second-recess and loads
a second-module housing a "fresh" cathode structure into the
second-recess. After the replacement is complete (which may be
detected manually by user input), the control subsystem 711
preferably updates the information stored in the management
subsystem 713 representative of the operational lifetime of the
fresh cathode structure.
[0092] The ionic-conducting medium may be integral to the
metal-fuel anode material and disposed in the first-module when
loaded into the first recess of the housing of the system. In such
systems, the refueling mode operations set forth above replace the
first-module to thereby load both fresh anode material and fresh
ionically-conducting medium into the first-recess in the housing of
the system.
[0093] Alternatively, the ionic-conducting medium may be integral
to the cathode structure(s) of the metal-air FCB cells and disposed
in the second-module when loaded into the second recess of the
housing of the system. In such systems, the cathode replacement
operations of the replace mode set forth above replace the
second-module to thereby load both fresh cathode structure(s) and
fresh ionically-conducting medium into the second-recess in the
housing of the system.
[0094] In another embodiment, the ionic-conducting medium may not
be integral to the anode material and the cathode structure(s) of
the metal-air FCB cells. In such systems, the cathode replacement
operations set forth above replace the second-module to thereby
load both fresh cathode structure(s) and fresh ionically-conducting
medium into the second-recess in the main housing of the FCB
subsystem.
[0095] In yet another embodiment of the invention, the
ionically-conducting medium may not be integral to the anode
material and the cathode structure(s) of the FCB cells. In such
systems, in the replace mode, the control subsystem 711 determines
that the ionically-conducting medium for one of the FCB subsystems
require replacement (preferably by monitoring the information
stored in the management subsystem 713 that is representative of
the operational lifetime of the particular ionically-conducting
medium) and communicates with the user, preferably via display 729,
to provide an indication that the identified ionically-conducting
medium requires replacement. For each identified
ionically-conducting medium requiring replacement, the user
manually replaces the ionically-conducting medium. After the
replacement is complete (which may be detected manually by user
input), the control subsystem 711 preferably updates the
information stored in the management subsystem 713 representative
of the operational lifetime of the fresh ionically-conducting
medium.
[0096] It should be understood that the control system 711 may
perform the operations for the various modes (discharge, recharge,
refuel, replace) described above in parallel with respect to
multiple FCB subsystems/modules/cells that can be independently
managed. For example, the control subsystem 711 can selectively
activate (via control bus 712) the discharge of a first set of the
metal-air FCB subsystems 708 and control the switching network 761
(via the signal path 737) to couple the power terminals
(preferably, the output power terminals) of these first set of
activated metal-air FCB subsystems 708 to the output power bus 706.
Concurrently therewith, the control subsystem 711 can selectively
activate (via control bus 712) the recharge of a second set of the
metal-air FCB subsystems 708 (disjoint from the first set of
metal-air FCB systems) and control the switching network 761 (via
the signal path 737) to couple the power terminals (preferably, the
input power terminals) of these second set of activated metal-air
FCB subsystems 708 to the input power bus 714.
[0097] Specific means for optimally carrying out such discharging,
recharging, refueling, ionically-conducting medium replacement, and
cathode replacement processes in metal-air FCB systems and devices
will be described in detail below in connection with the various
illustrative embodiments of the present invention.
[0098] The First Illustrative Embodiment of the Metal-Air FCB
System of the Present Invention
[0099] The first illustrative embodiment of the metal-air FCB
subsystem hereof is illustrated in FIG. 3. As shown, this FCB
subsystem 708" comprises an upper housing portion 616A (releasably)
detachable from a lower housing portion 616B. When attached these
two housing portions 616A and 616B form the main housing of this
FCB system. A four-element cathode structure 617 is manually
loadable/unloadable within a recess formed in the lower housing
portion 616B. An air-pervious panel (not shown) is formed in the
bottom side surface of the lower housing portion 616B for allowing
ambient air to flow through the cathode elements 620A through 620D
provided in cathode structure 617. A four-element anode contacting
structure 622 is preferably integrally-formed in the upper housing
portion, including a plurality of spring-biased electrical contacts
622A through 622D which are electrically connected to and
terminated in a second electrical connector 623 by way of a
plurality of electrical connectors.
[0100] The cathode structure 617 comprises a support frame 621 with
a plurality of recesses 630 each having a perforated bottom support
surface to enable passive air diffusion. The cathode elements 620A
through 620D terminate in a first electrical connector (not
shown).
[0101] A metal-fuel card 613, which is manually loadable/unloadable
within the recess in the housing formed between the cathode
structure 617 and the four-element anode contacting structure 622
(i.e., when the upper housing portion 616A is attached to the lower
housing portion 616B), carries a plurality of metal fuel elements
627A through 627D upon a support structure 628 having apertures
628A through 628D which allow the plurality of spring-biased
electrical contacts 622A through 622D to engage a respective
metal-fuel element 627A through 627D when the metal-fuel card is
slid within its recess as shown.
[0102] When metal-fuel card 613 and the cathode structure 617 are
slid into there respective recesses, an ionically-conducting medium
is disposed at least between the cathode elements 620A through 620D
and the corresponding metal-fuel elements 627A through 627B, the
ionically-conducting medium may be integrated with the metal-fuel
elements 627A through 627B (or integrated with the cathode elements
620A through 620D) by affixing a solid-state ionically-conducting
medium (such as an ionic-conducting polymer) to these metal-fuel
elements. Alternatively, the metal-fuel card 613 (or the cathode
structure 617) may have pads impregnated with an electrolyte (or
ionic-conducting gel made from am ionically-conducting polymer)
disposed thereon which act as the ionically-conducting medium.
Other solutions include disposing an electrolytic solution between
such structures. Preferably, the outer edge portions 632A (and
632B) of the cathode structure 617 and the metal-fuel card 613 are
each adapted to form a vapor tight seal with the module housing
when the cathode structure 617 and card 613 are loaded within the
module housing. This will prevent the electrolyte from evaporating
prior to discharging operations.
[0103] One or more printed circuit (PC) boards (two shown as 624
and 625), which may be mounted within the lower housing portion,
provides electrical connectors for establishing electrical contact
with the first and second electrical connectors 618 and 623
associated with the cathode structure 617 and the anode contacting
structure 622, respectively, and carry electronic circuitry for
discharging power to an output port 626A (and possibly recharging
from power delivered to input port 626B) with respect to the four
metal-air fuel cells disposed between the cathode structure 617 and
the anode contacting structure 622. This electronic circuitry may
include circuitry necessary for realizing output terminal
reconfiguration and output power control.
[0104] The Second Illustrative Embodiment of the Metal-Air FCB
System of the Present Invention
[0105] The second illustrative embodiment of the metal-air FCB
system hereof is illustrated in FIGS. 4 and 5. As shown in FIG. 4,
this metal-air FCB system 708'" comprises a number of subsystems,
namely a Metal-Fuel Tape Cassette Cartridge Loading[Unloading
Subsystem 401 for loading the metal-fuel tape cassette cartridge
403 to and from the system 708'". It comprises a number of
cooperating mechanisms, namely: a cassette receiving mechanism for
receiving the cassette cartridge 403 at a cassette insertion port
405 formed in system housing 407 by a user inserting the cassette
cartridge 403 into the port 405, and automatically withdrawing the
cartridge into the cassette storage bay therewithin; an automatic
door opening mechanism for opening a door 409 formed in the
cassette cartridge 403 (for metal-fuel tape access) when the
cartridge 403 is received within the cassette storage bay of the
FCB system; and an automatic cassette ejection mechanism for
returning the cassette cartridge 403 from the cassette storage bay
through the cassette insertion port 405 in response to a
predetermined condition (e.g., the depression of an "eject" button
provided on the front panel of the system housing, automatic
sensing of the end of the metal-fuel tape, etc.), where it is
manually removed from port 405 by the user.
[0106] In the illustrative embodiment of FIG. 4, the cassette
receiving mechanism can be realized as a platform-like carriage
structure that surrounds the exterior of the cassette cartridge
housing. The platform-like carriage structure can be supported on a
pair of parallel rails, by way of rollers, and translatable
therealong by way of an electric motor and cam mechanism. These
devices are operably connected to the system controller which will
be described in greater detail hereinafter. The function of the cam
mechanism is to convert rotational movement of the motor shaft into
a rectilinear motion necessary for translating the platform-like
carriage structure along the rails when a cassette is inserted
within the platform-like carriage structure. A proximity sensor,
mounted within the system housing, can be used to detect the
presence of the cassette cartridge being inserted through the
insertion port and placed within the platform-like carriage
structure. The signal produced from the proximity sensor can be
provided to the system controller in order to initiate the cassette
cartridge withdrawal process in an automated manner.
[0107] Within the system housing, the automatic door opening
mechanism can be realized by any suitable mechanism that can slide
the cassette door 409 into its open position when the cassette
cartridge is completely withdrawn into the cassette storage bay. In
the illustrative embodiment, the automatic cassette ejection
mechanism employs the same basic structures and functionalities of
the cassette receiving mechanism described above. The primary
difference is the automatic cassette ejection mechanism responds to
the depression of an "ejection" button provided on the front panel
of the system housing 407, or functionally equivalent triggering
condition or event. When the button is depressed, the control
subsystem (not shown) causes the Metal-Fuel Tape Discharging
Subsystem 411 (or the Metal-Fuel Tape Recharging Subsystem 413) to
withdraw its discharge heads (or recharge heads), and controls the
Tape Transport Subsystem 415 to transport the metal-fuel tape 402
back to the cassette cartridge 403; and the cassette cartridge
automatically returns from the cassette storage bay, through the
cassette insertion port 405.
[0108] The Metal-Fuel Tape Discharging Subsystem 411 generates
electrical power from the metal-fuel tape 402 during the discharge
mode of operation, and supplies that power to a DC output power bus
706'. The Metal-Fuel Tape Recharging Subsystem 413
electro-chemically recharging (i.e. reducing) sections of oxidized
metal-fuel tape 402 during the recharge mode of operation using
electrical power provided on the DC input power bus 711'.
[0109] The Metal-Fuel Tape Discharging Subsystem 411 preferably
uses an assembly of discharging heads (cathode structures) for
discharging metal-fuel tape in the presence of air (02) and an
ionically-conducting medium and generating electrical power across
an electrical power-consuming load connected to the FCB system. The
Metal-Fuel Tape Recharging Subsystem 413 preferably uses an
assembly of recharging heads (cathode structures) for recharging
metal-fuel tape in the presence of air (O.sub.2) and an
ionically-conducting medium and electrical power. While it may be
desirable in some applications to avoid or suspend tape recharging
operations while carrying out tape discharging operations, the FCB
system of the first illustrative embodiment enables concurrent
operation of the discharging and discharging modes. Notably, this
feature of the present invention enables simultaneous discharging
and recharging of metal-fuel tape during power generating
operation.
[0110] The ionically-conducting medium may be integral to the
metal-fuel anode tape 402 stored in the cassette cartridge 403 when
inserted into the port 405 by the user and when loaded into the
Metal-Fuel Tape Discharging Subsystem 411 (and the Metal-Fuel Tape
Recharging System 413) during discharging operations (and
recharging operations). This may be realized by affixing a
solid-state ionically-conducting film (such as an
ionically-conducting polymer) to the surface of the metal-fuel
anode tape 402 so that is disposed between the cathode structure
and the metal-fuel anode tape during discharging and recharging
operations. In an alternate embodiments, the solid-state
ionically-conducting medium can be formed on the cathode
structures, or be realized as a separate tape structure, or be
realized as an ionically-conducting liquid or gel that is disposed
between the cathode structures and the metal-fuel anode tape.
[0111] The Metal-Fuel Tape Discharging Subsystem 411 (and the
Metal-Fuel Tape Recharging System 413) may utilize cathode
structures that are stationary relative to the moving tape 402
during the discharging (and recharging operations). It should also
be noted that the Metal-Fuel Tape Discharging Subsystem 411 may
include circuitry necessary for realizing output power control of
the power generated by the multiple discharging head assembly
(which selectively controls the power provided to the DC output
power bus).
[0112] Alternatively, the Metal-Fuel Tape Discharging Subsystem 411
(and the Metal-Fuel Tape Recharging System 413) may utilize cathode
structures that move relative to the moving tape 402 during the
discharging (and recharging operations). An example of such a
system is illustrated in FIG. 5 wherein the cathode structure 501
is realized as a cylindrical cathode structure 503 having a hollow
center with perforations in the surface thereof to permit oxygen
transport to the interface formed between an ionically-conducting
medium and the metal fuel tape 402' transported thereover.
[0113] As shown in FIG. 5, the cylindrical cathode structure 501
comprises a cathode element, preferably made from nickel mesh
fabric embedded within carbon and catalytic material, mounted over
the outer surface of the cylindrical perforated hollow cylinder
503. The cathode cylinder 501 is rotated about its axis of rotation
by a cathode drive unit 505. As shown the cathode drive unit 505
has a drive shaft 507 with a gear 509 that engages teeth formed on
the edge of the cylindrical cathode 501.
[0114] The metal-fuel tape 402' is transported over the surface of
the cylindrical cathode 501. An electrically-conductive
"cathode-contacting" element 523 is arranged in electrical-contact
with the nickel mesh fabric of the cylindrical cathode 501 and is
electrically connected to conductor 517 (e.g. wiring) which
terminates at output power controller 515. In addition, an
electrically-conductive anode-contacting element 521 is arranged
closely adjacent to the cylindrical cathode 501 and in electrical
contact with the underside of the metal-fuel tape 402'. The
anode-contacting element 521 is electrically-connected to conductor
519 which terminates at the output power controller 515. The output
power-controller 515 provides power to the DC output power bus 706'
in the discharge mode of operation.
[0115] During the discharge mode of operation, oxygen-rich air is
permitted to flow through the hollow core of the cylindrical
cathode 501 and reach the interface between the
ionically-conducting medium and the metal-fuel tape 402'. The
metal-fuel tape 402' is transported over the surface of the
cylindrical cathode 501 by a fuel-tape transporter 511. The cathode
drive unit 505 and the fuel tape transporter 511 are controlled by
a system controller 513 so that the metal-fuel tape 402, the
cathode structure 501 and the ionically-conducting medium disposed
therebetween are transported at substantially the same velocity at
the locus of points at which the ionically-conducting medium
contacts the metal-fuel tape 402 and the cathode structure 501.
This condition of operation substantially reduces the generation of
frictional (e.g., shear) forces among the system components, which
results in a reduction in: the amount of electrical power required
to transport the cathode structures, metal-fuel tape and
ionically-conducting medium during system operation; the shedding
of metal-oxide particles from the metal-fuel tape and the embedding
of such particles in the porous structure of the cathode; and the
likelihood of damaging the cathode structures and metal fuel 402'
of the FCB system.
[0116] The same structures (or similar structures) are used to
realize the Metal-Air Fuel Recharging System.
[0117] It should be noted that the Metal-Fuel Tape Discharging
Subsystem may include multiple cylindrical cathode discharging
structures as described above. In such system, the output power
controller 515 may include circuitry necessary for realizing output
power control of the power generated by the multiple discharging
cathode assemblies (which selectively controls the power provided
to the DC output power bus).
[0118] It should also be noted that the discharge head assembly (or
assemblies) of the Metal-Fuel Tape Discharging System may be
readily replaceable via manual insertion (and removal) from a
recess in the housing of the metal-air FCB subsystem.
[0119] The Third Illustrative Embodiment of the Metal-Air FCB
System of the Present Invention
[0120] The third illustrative embodiment of the metal-air FCB
system hereof is illustrated in FIGS. 6 and 7. As shown in FIG. 6,
this metal-air FCB system 708"" comprises a number of subsystems,
namely a Metal-Fuel Paste Holder, a Metal-Fuel Paste Discharging
System, and a Metal-Fuel Paste Loading System. The Metal-Paste
Holder comprises a container 801 including a paste-compartment 803
(disposed within the container 801) that holds metal anode material
in fluid form (for example, formed by suspending particles of metal
in a fluid electrolyte, such as KOH and varying additives, to
thereby form a paste-like substance). The paste-compartment 803 can
be moved within the container 801 such that the paste stored
therein is exposed to a discharging head assembly comprising at
least one anode-contacting element 805 and cathode structure 807
via a first-aperture 809 and second-aperture 811 formed in the
container structure. Preferably, the paste-compartment 803 is
formed by a pair of walls 813,815 fixed apart by one or more
supporting members 817 (one shown). In addition, the geometry of
the walls 813,815 fit the inner surface of the container 801 to
allow rectilinear movement within the container 801 to thereby
expose the metal-fuel paste to the anode-contacting element 805 and
cathode structure 807 via the first-aperture 809 and
second-aperture 811, respectively. A passage (not shown) is
provided to transport ambient air (oxygen) to the cathode-element
805 for discharging operations.
[0121] Rectilinear movement of the paste-compartment 803 can be
realized by a helical screw 818 coupled to one the walls (for
example, wall 813 as shown) and translation therealong by way of an
electric motor 819 and gear mechanism. Preferably, the devices are
operably connected to the control subsystem 711'. The function of
the gear mechanism is to convert rotational movement of the motor
shaft into a rectilinear motion necessary for translating the
paste-compartment 803 within the container 801.
[0122] Preferably, the container 801 and the anode-contacting
element 805 and cathode structure 807 of the discharge-head
assembly have a modular construction that provides for
user-friendly loading and unloading of metal-fuel and/or
user-friendly replacement of the cathodes and possibly the
anode-contacting elements.
[0123] An exemplary modular construction is illustrated in FIG. 7
wherein an upper-housing portion 825 is (releasably) detachable
from a lower-housing portion 827. The housing portions 825,827
include grooves 829, 831 that form a first-recess when the housing
portions 825,827 are attached. The paste-container 801 is manually
loaded into the first-recess by sliding the paste-container 801
therein. The container 801 includes the first-aperture 809 and
second-aperture 811 that aligns with the anode-contacting element
805 and cathode structure 807 of the discharge-head assembly when
the container 801 is inserted to the first-recess.
[0124] Preferably, the cathode structure 807 and the
anode-contacting element 805 of the discharge head assembly are
removable. This may be realized by grooves 833, 835 in the housing
portions 825,827, respectively, that form a second-recess when the
housing portions 825,827 are attached. The cathode structure 807
and the anode-contacting element 805 are integrated on one or more
supporting members (two shown as 821 and 823) that are manually
loaded into the second-recess by sliding the supporting member(s)
into the second-recess.
[0125] The cathode structure 807 preferably includes a nickel mesh
fabric embedded within carbon and catalytic material that is
mounted over the surface of the supporting member 823 that aligns
with the aperture 811 of the container 801 when the container 801
is loaded into the first-recess as shown. In addition, the
supporting member 823 includes a passageway 824 that enables
transport of air (oxygen) to the cathode structure 825 formed
thereon. The anode-contacting element 805 preferably comprises a
metal layer formed on the surface of the supporting member 821 that
aligns with the aperture 809 of the container 801 when the
container 801 is loaded into the first-recess as shown. The cathode
structure 825 and the anode-contacting element 823 are
electrically-connected to the DC output power bus 706' in the
discharge mode of operation.
[0126] In the refuel mode of operation, a container 801 storing
consumed metal-fuel is manually removed from the first-recess in
the housing and a container 801 storing fresh fuel is loaded into
the first recess of the housing. Preferably, when loaded, the paste
compartment 803 is positioned such that it is not exposed to the
discharge head assembly.
[0127] During the discharge mode of operation, oxygen-rich air is
permitted to flow through the passageway 824 and reach the
discharge head assembly. The metal-fuel paste compartment 803 is
transported by the Metal-Fuel Paste Loading System such that the
metal-fuel paste contained therein is exposed to the discharge head
assembly thereby discharging power via the CD output power bus.
When operated in this manner, consumed paste material is disposed
at the opposite end of the container 801.
[0128] The same structures (or similar structures) may be used to
realize a Metal-Air Fuel Recharging System wherein power is
provided to one or more recharge head assemblies and the
metal-paste exposed therein is recharged (e.g., the metal-oxide is
converted back to metal and oxygen is emitted from the passageway
that vents the cathode structure of the recharge head
assemblies).
[0129] It should be noted that the Metal-Fuel Tape Discharging
Subsystem may include multiple cathode discharging structures as
described above. In such system, the cathode structures and
anode-contacting elements may terminate at an output power
controller that includes circuitry necessary for realizing output
power control of the power generated by the multiple discharging
cathode assemblies (which selectively controls the power provided
to the DC output power bus).
[0130] In addition, it is contemplated that the container 801 and
housing (depicted as housing portions 825,827) may embody the
reservoir container and fluid transport paths to thereby provide
for a more compact storage of the fresh paste material and consumed
paste material. In such a structure, consumed paste material may be
transported to a second compartment in the container (disposed at
the near-end of the container adjacent to insertion point of the
container) via a transport path integral to the housing. In this
case, the transport path carries consumed paste material from the
far-end of the container adjacent to the discharge head assembly to
the second compartment. The volume of the two compartments may vary
in an inverse relationship to thereby minimize the space required
therein as taught therein.
[0131] Applications of the Metal-Air FCB Based Power Supply Unit of
the Present Application
[0132] Only a few illustrative embodiment of the present invention
have been described above. Numerous other embodiments of the
present invention may be practiced by others having the benefit of
the present disclosure and novel teachings disclosed therein. In
general, the designs, structures, and inventive principles embodied
within the system embodiments described above can be used to create
various types of metal-air FCB power producing (i.e., generating)
modules adapted for use within various electric systems and
applications. Examples of such FCB power generating modules
comprise, in general: a module housing one or more FCB subsystems
into which anode material is loaded for discharging; and wherein
the module has a pair of electrical terminals for contacting power
terminals of the host system.
[0133] Devices/Systems with the Integrated Metal-Air FCB Based
Power Supply Unit of the Present Invention
[0134] In FIG. 8, there is shown a computer processing apparatus
900' (for example, a server providing processing capability to an
enterprise) having an integrated metal-air FCB based power supply
unit 700'. Line AC power is supplied to the power supply unit 700'.
The output port 755' of the integrated metal-air FCB based power
supply provides regulated power to the various devices
(motherboard, CPU memory, hard disk drive, floppy disk drive,
optical drive, peripheral devices, etc) of the computer processing
apparatus. In this application, the metal-air FCB based power
supply unit 700' provides the functionality of an integrated UPS
system for the computer processing apparatus. As shown in FIG. 8,
the metal-air FCB based power supply unit 700' has a plurality of
recesses for slidably removing and loading replacement cathode
structures 617' and/or replacement metal-fuel anode cards 613' into
the system 900'.
[0135] Similarly, the apparatus 900' of FIG. 8 may comprise a
television, audio equipment, washing machine, refrigerator,
freezer, oven, stove, furnace, air conditioner, an
electrically-powered tool, or any other home/garden appliance. In
such systems, the output port 755' of the integrated metal-air FCB
based power supply provides regulated power to the various devices
of the apparatus.
[0136] In FIG. 9, there is shown a portable appliance 900" (for
example, a wireless communication device) having an integrated
metal-air FCB based power supply unit 700". An external power
source (Line In) is supplied to the power supply unit 700". The
output port (not shown) of the integrated metal-air FCB based power
supply provides regulated power to the various components (wireless
communication chipsets, memory, controller, LCD screen, keypad,
etc) of the device. In this application, the metal-air FCB based
power supply unit 700" provides the functionality of an integrated
UPS system for the device. As shown in FIG. 9, the metal-air FCB
based power supply unit 700" has recesses (one shown) for slidably
removing and loading replacement metal-fuel anode cards 613' (and,
possibly replacement cathode structures 617' ) into the device
900". Note that the power supply unit 700" can be portable (as
shown) so that it can be used as an alternate source of power for
multiple portable devices as needed. However, note that the overall
size of the module 700" in any particular application need not be
any larger that the dimensions of the compartment to which it is to
be installed, which includes hand-held devices and the like.
[0137] Similarly, the apparatus 900" of FIG. 9 may comprise a
radio, disc player, other music playing devices, television,
camcorder, other video playing/recording devices, telephone, PDA,
other communication devices, or any other portable electronic
device. In such devices, the output port of the integrated
metal-air FCB based power supply provides regulated power to the
various components of such devices.
[0138] Advantageously, devices/systems having an integrated
metal-air FCB based power supply unit as described above provide
improved efficiency and reliability over prior art devices/systems.
More specifically, in the event that a prolonged interruption
occurs in the power delivered by an external power source, such
devices/systems can be used without prolonged interruption by
refueling the metal-air FCB based power supply unit integrated
therein, if need be. Moreover, the environmental and safety
hazards, costs, unfriendly noises and other limitations associated
with the prior forms of auxiliary power generation (based upon
conventional battery technology and combustible fuel) are avoided.
In addition, the metal-air FCB subsystem of the present invention
preferably embodied therein provides a modular architecture to
enable flexible and user-friendly operations in loading of
metal-fuel, unloading of consumed metal-fuel, replacement of the
ionic-conducting medium, and replacement of the cathode structures
of the metal-air FCB cells.
[0139] Uninterruptible Power Generation and Distribution Systems
with a Metal-Air FCB Based Power Supply Unit
[0140] In FIG. 10, there is shown an uninterruptible power
generation system including an interruptible power source 953'
(which may be wind-driven power generator as shown, or a
solar-based power generator, or a hydroelectric generation system)
coupled to a metal-air FCB based power supply unit 700'. The power
supply unit 700' is electrically coupled to the one or more
electrical power-consuming load devices via an output port 755'. As
shown in FIG. 10, the metal-air FCB based power supply unit 700'
has a plurality of recesses for slidably removing and loading
replacement cathode structures 617' and/or metal-fuel anode cards
613' into the system.
[0141] In FIG. 11, there is shown an uninterruptible power
distribution system 950' (for example, in a residence) including an
interruptible power source 953' (the utility maintained power grid)
coupled to a metal-air FCB based power supply unit 700'. The output
port 755' of the power supply unit 700' is electrically coupled to
the terminals (bus bars) of a power distribution panel 1001
providing power distribution to the electrical power-consuming
loads (outlets, lights, appliances, security and fire systems) of
the building. As shown in FIG. 11, the metal-air FCB power
producing module 700' has a plurality of recesses for slidably
removing and loading replacement cathode structures and/or
replacement metal-fuel anode cards 613' into the system.
[0142] Advantageously, uninterruptible power generation and
distribution systems with a metal-air FCB based power supply unit
as described above provide improved efficiency and flexibility over
prior art power generation systems. More specifically, in the event
that a prolonged interruption occurs in the power delivered by an
interruptible power source, the power generation and distribution
system of the present invention can be used without prolonged
interruption by refueling the metal-air FCB based power supply unit
integrated therein, if need be. Moreover, the environmental and
safety hazards, costs, unfriendly noises and other limitations
associated with the prior art forms of auxiliary power generation
(based upon conventional battery technology and combustible fuel)
are avoided. In addition, the metal-air FCB subsystem of the
present invention preferably embodied therein provides a modular
architecture to enable flexible and user-friendly operations in
loading of metal-fuel, unloading of consumed metal-fuel,
replacement of the ionic-conducting medium, and replacement of the
cathode structures of the metal-air FCB cells.
[0143] Having described in detail the various aspects of the
present invention described above, it is understood that
modifications to the illustrative embodiments will readily occur to
persons with ordinary skill in the art having had the benefit of
the present disclosure. All such modifications and variations are
deemed to be within the scope and spirit of the present invention
as defined by the accompanying claims to Invention.
* * * * *