U.S. patent application number 10/629929 was filed with the patent office on 2004-02-05 for air manager system for metal air battery.
This patent application is currently assigned to The Gillette Company, a Delaware corporation. Invention is credited to Molloy, Kevin, Thompson, John A., Yonjan, Bikram, Yoppolo, Robert.
Application Number | 20040023103 10/629929 |
Document ID | / |
Family ID | 23581896 |
Filed Date | 2004-02-05 |
United States Patent
Application |
20040023103 |
Kind Code |
A1 |
Molloy, Kevin ; et
al. |
February 5, 2004 |
Air manager system for metal air battery
Abstract
An air manager system for a metal air cell is disclosed. The
system includes: (a) a housing having an air mover and an air
outlet opening; and (b) a cartridge that is removable from the
housing. The cartridge includes (i) a metal air cell; (ii) an air
inlet opening located toward a first end of the cartridge and
adjacent to a first side of the cartridge; (iii) an air outlet
opening located toward a second end of the cartridge and adjacent
to a second side of the cartridge; (iv) a first diffusion tube
communicating with the air inlet opening of the cartridge, the
first diffusion tube extending along the first side of the
cartridge; (v) a second diffusion tube communicating with the air
outlet opening of the cartridge, the second diffusion tube
extending along the second side of the cartridge; (vi) a first
distributor tube communicating with the first diffusion tube, the
first distributor tube extending from the first diffusion tube
along the first side of the cartridge through a change of direction
and being adjacent to an air plenum, the first distributor tube
including a plurality of openings communicating with the air
plenum; and (vii) a second distributor tube communicating with the
second diffusion tube, the second distributor tube extending from
the second diffusion tube along the second side of the cartridge
through a change of direction and being adjacent to the air plenum,
the second distributor tube including a plurality of openings
communicating with the air plenum.
Inventors: |
Molloy, Kevin; (Canton,
MA) ; Thompson, John A.; (Peachtree City, GA)
; Yonjan, Bikram; (Watertown, MA) ; Yoppolo,
Robert; (Woonsocket, RI) |
Correspondence
Address: |
FISH & RICHARDSON PC
225 FRANKLIN ST
BOSTON
MA
02110
US
|
Assignee: |
The Gillette Company, a Delaware
corporation
|
Family ID: |
23581896 |
Appl. No.: |
10/629929 |
Filed: |
July 29, 2003 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10629929 |
Jul 29, 2003 |
|
|
|
09400020 |
Sep 21, 1999 |
|
|
|
6641947 |
|
|
|
|
Current U.S.
Class: |
429/403 ;
429/431; 429/444; 429/456; 429/88 |
Current CPC
Class: |
H01M 10/647 20150401;
H01M 12/065 20130101; Y02E 60/50 20130101; H01M 12/06 20130101;
Y02E 60/10 20130101; H01M 10/6565 20150401; H01M 10/658 20150401;
H01M 10/6566 20150401; H01M 8/04089 20130101; H01M 10/6563
20150401; H01M 10/6557 20150401 |
Class at
Publication: |
429/38 ; 429/88;
429/27 |
International
Class: |
H01M 008/24; H01M
012/06; H01M 002/12 |
Claims
What is claimed is:
1. An air manager system for a metal air cell comprising: (a) a
housing having an air mover and an air outlet opening; (b) a
cartridge that is removable from said housing, said cartridge
having first and second ends, first and second sides, and (i) a
metal air cell; (ii) an air inlet opening located toward said first
end of said cartridge and adjacent to said first side of said
cartridge; (iii) an air outlet opening located toward said second
end of said cartridge and adjacent to said second side of said
cartridge; (iv) a first diffusion tube communicating with said air
inlet opening of said cartridge, said first diffusion tube
extending along said first side of said cartridge; (v) a second
diffusion tube communicating with said air outlet opening of said
cartridge, said second diffusion tube extending along said second
side of said cartridge; (vi) a first distributor tube communicating
with said first diffusion tube, said first distributor tube
extending from said first diffusion tube along said first side of
said cartridge through a change of direction and being adjacent to
an air plenum, said first distributor tube including a plurality of
openings communicating with said air plenum; and (vii) a second
distributor tube communicating with said second diffusion tube,
said second distributor tube extending from said second diffusion
tube along said second side of said cartridge through a change of
direction and being adjacent to said air plenum, said second
distributor tube including a plurality of openings communicating
with said air plenum.
2. The air manager system of claim 1, wherein said cartridge
further comprises (a) a first panel defining said openings of said
first distributor tube, wherein said first panel includes a ridge,
and wherein said first panel and said ridge form two walls of said
first diffusion tube and two walls of said first distributor tube;
and (b) a second panel defining said openings of said second
distributor tube, wherein said second panel includes a ridge, and
wherein said second panel and said ridge form two walls of said
second diffusion tube and two walls of said second distributor
tube.
3. The air manager system of claim 1, wherein said diffusion tubes,
said distributor tubes, and said openings cooperate to define a
plurality of air flow paths through said cartridge, all of said
paths being substantially equal in length.
4. The air manager system of claim 1, wherein said air mover in
said housing moves air into said air inlet opening of said
cartridge.
5. The air manager system of claim 4, wherein said air mover is a
blower.
6. The air manager system of claim 1, wherein said air mover in
said housing extracts air from said air outlet opening of said
cartridge.
7. The air manager system of claim 1, wherein said diffusion tubes
are sized to permit an air flow rate therethrough of less than
about 3.46.times.10.sup.-2 L/hour when said air mover is off.
8. The air manager system of claim 7, wherein said diffusion tubes
are sized to permit an air flow rate therethrough of less than
about 3.46.times.10.sup.-3 L/hour when said air mover is off.
9. The air manager system of claim 1, wherein each of said
diffusion tubes has a cross-sectional area of about 1 mm.sup.2 to
about 8 mm.sup.2 and a length of about 10 mm to about 70 mm.
10. The air manager system of claim 1, wherein said cartridge
comprises a plurality of metal air cells.
11. The air manager system of claim 10, wherein said cells are
positioned in stacks, and wherein each stack includes 2 cells that
are spaced apart vertically to define an air flow path
therebetween.
12. The air manager system of claim 11, wherein said cartridge
comprises two stacks of cells, wherein said stacks are spaced apart
horizontally.
13. The air manager system of claim 10, wherein said cells
cooperate to define a battery that delivers a current of at least
300 mA when said air mover is on.
14. The air manager system of claim 13, wherein said cells
cooperate to define a battery that delivers a current of at least
500 mA when said air mover is on.
15. The air manager system of claim 14, wherein said cells
cooperate to define a battery that delivers a current of at least
1000 mA when said air mover is on.
16. The air manager system of claim 15, wherein said cells
cooperate to define a battery that delivers an average current of
about 1700 mA when said air mover is on.
17. The air manager system of claim 13, wherein said battery has an
output current density of about 1 to 200 mA/cm.sup.2 of air cathode
surface when said air mover is on.
18. The air manager system of claim 17, wherein said battery has an
output current density of about 10 to 110 mA/cm.sup.2 of air
cathode surface when said air mover is on.
19. The air manager system of claim 1, wherein said air mover
generates an air flow rate through said cartridge of about 0.04 to
40 L/hour.
20. The air manager system of claim 19, wherein said air mover
generates an air flow rate through said cartridge of about 4 to 40
L/hour.
21. The air manager system of claim 1, wherein said housing and
said cartridge are configured such that when said cartridge is
placed in said housing, said air outlet opening in said housing and
said air inlet opening in said cartridge are substantially
aligned.
22. The air manager system of claim 21, wherein said housing
further comprises a cartridge release element that allows air to
exit said housing.
23. The air manager system of claim 22, wherein said cartridge
further comprises a locking tab that is configured to interlock
with said cartridge release element.
24. An air manager system for a metal air cell comprising: (a) a
housing having an air mover and an air outlet opening; (b) a
cartridge that is removable from said housing, said cartridge
having (i) a metal air cell; (ii) an air inlet opening; (iii) an
air outlet opening; (iv) a first diffusion tube in communication
with said air inlet opening and a second diffusion tube in
communication with said air outlet opening; (v) a first distributor
tube in communication with said first diffusion tube and a second
distributor tube in communication with said second diffusion tube;
and (vi) a first panel defining a plurality of openings
communicating with said first distributor tube and a second panel
defining a plurality of openings communicating with said second
distributor tube, wherein said diffusion tubes, said distributor
tubes, and said openings cooperate to define a plurality of air
flow paths from said air inlet opening of said cartridge, through
said cartridge, to said air outlet opening of said cartridge, all
of said paths being substantially equal in length.
25. A method for controlling air flow in a metal air battery
comprising: (a) confining at least one metal air cell within a
cartridge, said cartridge having an air inlet opening and an air
outlet opening; and (b) moving air through any of a plurality of
air flow paths within said cartridge, wherein each of said paths
passes through said air inlet opening of said cartridge, through a
diffusion tube, through a distributor tube, across an active
surface of a cell, and through said air outlet opening of said
cartridge, and wherein all of said paths are substantially equal in
length.
26. The method of claim 25, wherein each of said air flow paths
passes through two diffusion tubes and two distributor tubes.
27. The method of claim 25, wherein each of said air flow paths
passes through an opening in a panel.
28. The method of claim 25, wherein air is moved through said
cartridge by an air mover exterior to said cartridge.
29. The method of claim 28, wherein said air mover pushes air into
said cartridge.
30. The method of claim 29, wherein said air mover extracts air
from said cartridge.
31. The method of claim 25, wherein step (b) includes moving air
through a diffusion tube, changing the direction of air flow
180.degree., then moving air through a distributor tube.
32. The method of claim 31, wherein step (b) includes moving air
through a diffusion tube, changing the direction of air flow
180.degree., moving air through a distributor tube, changing the
direction of air flow 90.degree., then moving air across an active
surface of a metal-air cell.
Description
BACKGROUND OF THE INVENTION
[0001] The invention generally relates to an air manager system for
a metal air battery.
[0002] Batteries are commonly used electrical energy sources. A
battery contains a negative electrode, typically called the anode,
and a positive electrode, typically called the cathode. The anode
contains an active material that can be oxidized; the cathode
contains or consumes an active material that can be reduced. The
anode active material is capable of reducing the cathode active
material. In order to prevent direct reaction of the anode material
and the cathode material, the anode and the cathode are
electrically isolated from each other by a sheet-like layer,
typically called the separator.
[0003] When a battery is used as an electrical energy source in a
device, such as a cellular telephone, electrical contact is made to
the anode and the cathode, allowing electrons to flow through the
device and permitting the respective oxidation and reduction
reactions to occur to provide electrical power. An electrolyte in
contact with the anode and the cathode contains ions that flow
through the separator between the electrodes to maintain charge
balance throughout the battery during discharge.
[0004] In a metal air electrochemical cell, oxygen is reduced at
the cathode, and a metal is oxidized at the anode. Oxygen is
supplied to the cathode from the atmospheric air external to the
cell through one or several air access port(s) in the
container.
[0005] During periods of inactivity, there is no need for air from
the environment to diffuse into the cell. In fact, it is preferred
that the supply of air to the cell be minimized, because the
diffusion of air into the cell can lead to changes in the humidity
level of the cell. When the humidity level of the outside
atmosphere is lower than that of the cell, the cell can dry out.
When the humidity level of the outside atmosphere is higher than
that of the cell, the cell can flood. In addition, when air
diffuses into the cell, the anode can become prematurely
oxidized.
[0006] An air manager system enhances the activated storage life of
a metal-air battery system by controlling the flow of air, which
includes oxygen, carbon dioxide, and water, into and out of the
system. During periods of battery use, an air mover, such as a fan,
moves enough air into and out of the system to ensure good
performance.
[0007] The distribution of air flow across the active surfaces of
the cells can be uneven. Uneven air flow can result in "hot spots"
in the battery, where the anode and the cathode react more than in
other areas of the battery. Hot spots can lead to inconsistent
battery performance and failure to realize the maximum capacity of
the battery.
SUMMARY OF THE INVENTION
[0008] The air manager system of the invention provides for
improved activated storage life of the battery contained in the
system and provides for good performance of the battery during use.
Air is directed across active surfaces of the battery evenly, thus
optimizing performance. In addition, the system is designed for
ease of use by the consumer.
[0009] In one aspect, the invention features an air manager system
for a metal air cell. The system includes: (a) a housing having an
air mover and an air outlet opening; and (b) a cartridge that is
removable from the housing. The cartridge includes (i) a metal air
cell; (ii) an air inlet opening located toward a first end of the
cartridge and adjacent to a first side of the cartridge; (iii) an
air outlet opening located toward a second end of the cartridge and
adjacent to a second side of the cartridge; (iv) a first diffusion
tube communicating with the air inlet opening of the cartridge, the
first diffusion tube extending along the first side of the
cartridge; (v) a second diffusion tube communicating with the air
outlet opening of the cartridge, the second diffusion tube
extending along the second side of the cartridge; (vi) a first
distributor tube communicating with the first diffusion tube, the
first distributor tube extending from the first diffusion tube
along the first side of the cartridge through a change of direction
and being adjacent to an air plenum, the first distributor tube
including a plurality of openings communicating with the air
plenum; and (vii) a second distributor tube communicating with the
second diffusion tube, the second distributor tube extending from
the second diffusion tube along the second side of the cartridge
through a change of direction and being adjacent to the air plenum,
the second distributor tube including a plurality of openings
communicating with the air plenum.
[0010] The air mover can move air into the air inlet opening of the
cartridge and/or extract air from the air outlet opening of the
cartridge. The diffusion tube or tubes help to minimize the
transport of water vapor into and out of the cartridge during
periods of inactivity. The diffusion tubes therefore help to
prevent the cells from flooding or drying out.
[0011] When the metal air cell has been depleted, the cartridge can
be removed from the housing and replaced with a fresh cartridge.
The housing, including the air mover, can be re-used with the new
cartridge, instead of being replaced. This design helps to minimize
the cost of using the air manager system. It also reduces the size
of the cartridge, which in turn minimizes the amount of waste
generated when the cartridge must be replaced.
[0012] In another aspect, the invention features an air manager
system for a metal air cell. The system includes: (a) a housing
having an air mover and an air outlet opening; and (b) a cartridge
that is removable from the housing. The cartridge includes (i) a
metal air cell; (ii) an air inlet opening; (iii) an air outlet
opening; (iv) a first diffusion tube in communication with the air
inlet opening and a second diffusion tube in communication with the
air outlet opening; (v) a first distributor tube in communication
with the first diffusion tube and a second distributor tube in
communication with the second diffusion tube; and (vi) a first
panel defining a plurality of openings communicating with the first
distributor tube and a second panel defining a plurality of
openings communicating with the second distributor tube. The
diffusion tubes, the distributor tubes, and the openings cooperate
to define a plurality of air flow paths that start at the air inlet
opening of the cartridge, continue through the cartridge, and end
at the air outlet opening of the cartridge. All of these air flow
paths are substantially equal in length.
[0013] In another aspect, the invention features a method for
controlling air flow in a metal air battery. The method includes:
(a) confining at least one metal air cell within a cartridge having
an air inlet opening and an air outlet opening; and (b) moving air
through any of a plurality of air flow paths within the cartridge.
Each of these air flow paths passes through the air inlet opening
of the cartridge, through a diffusion tube, through a distributor
tube, across an active surface of a cell, and through the air
outlet opening of the cartridge. All of the air flow paths are
substantially equal in length. The method can include moving air
into the air inlet opening of the cartridge and/or extracting air
from the air outlet opening of the cartridge.
[0014] Air from the atmosphere is forced into the cartridge by air
discharged from an air mover, such as a blower, or pulled out of
the cartridge as intake air supplied to an air mover, such as a
vacuum device. It flows across the active surface of the cell
contained in the cartridge, then exits the cartridge, rather than
being recycled through the cartridge.
[0015] As used herein, "removable" means that a component can be
easily removed, for example, by a consumer, without the need for
tools or excessive force.
[0016] As used herein, "toward" means at a position on a member,
relative to a given point on that member, within 30%, more
preferably 20% or 10%, of the total length of the member. A feature
located toward an end of a bar having a length of 10 cm is within 3
cm of that end of the bar, and is preferably 2 cm or 1 cm from the
end.
[0017] Other features and advantages of the invention will be
apparent from the description of the preferred embodiment thereof,
and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is an exploded view of a cartridge of the
invention.
[0019] FIG. 2 is a cutaway view of a cartridge of the
invention.
[0020] FIG. 3 is a top cross sectional view of a cartridge of the
invention.
[0021] FIG. 4 is an exploded view of an air manager system of the
invention.
[0022] FIG. 5 is a pictorial view of an air manager system of the
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The air manager system of the invention can be used with
devices such as cellular telephones. Air is directed across the
active surfaces of the metal air cells uniformly, so relatively
consistent battery performance can be achieved.
[0024] Referring to FIG. 1, a cartridge includes a lower casing 2
and an upper casing 4. The cartridge may be made of any material
that is impermeable to air, such as plastic or metal, or a
combination thereof. Four metal air cells 6 are contained within
the cartridge. Any type of metal-air cell, for example, prismatic
cells, button cells, cylindrical cells, and bipolar construction
cells can be used. The cells can be prepared, for example, as
described in Linden, Handbook of Batteries, 2d ed. (1995). The
cells are arranged in stacks of two. The cells within each stack
are spaced apart vertically to define an air flow path 8 between
the cells in the stack. The cathodes (the active surfaces) of these
cells face each other within these stacks. The stacks are spaced
apart horizontally.
[0025] An interior panel 10 of the cartridge has a plurality of
openings 12. In addition, panel 10 has a ridge 14. When assembled,
panel 10, ridge 14, and cartridge wall 16 define a long, thin path
that serves as a diffusion tube and as a distributor tube for the
cartridge. The openings 12 communicate with the distributor
tube.
[0026] Interior panel 20 also includes a ridge (not shown).
Interior panel 20, the ridge, and cartridge wall 22 define an air
exit plenum that includes a second distributor tube and a second
diffusion tube. Interior panel 20 has openings 24 that communicate
with the distributor tube. In this embodiment, the diffusion tubes
and the distributor tubes are integrated into the cartridge and
therefore cannot be removed from the cartridge. This design is
space efficient, and cartridges with this design are relatively
inexpensive to produce.
[0027] Referring to FIG. 2, air flows into the air inlet opening of
the cartridge, as indicated by arrow 25. It flows along the length
of the diffusion tube 26, then turns about 180.degree.. It flows
through distributor tube 28, turns about 90.degree., then flows
through the openings 12. After the air flows across the cells, it
is collected in a second distributor tube (not shown). It turns
about 180.degree., flows through a second diffusion tube (not
shown), then exits the cartridge through the air outlet opening, as
indicated by arrow 31.
[0028] The diffusion tubes and distributor tubes are connected
through approximately 180.degree. turns. The turns make the air
paths relatively convoluted, and therefore help to increase the
isolation of the cells when the fan is off.
[0029] Referring to FIG. 3, the air flow paths through the
cartridge are shown in more detail. Air enters the cartridge
through air inlet opening 46. The air flows through a diffusion
tube (not shown), through a distributor tube (not shown), and
through openings 12. For clarity, not all of the openings are
shown. The air flows across the cells, then through openings 24.
The air then flows through a second distributor tube (not shown),
through a second diffusion tube, then through air outlet opening
48.
[0030] As shown in FIG. 3, air can take any of air flow paths a, b,
or c when flowing through the cartridge. The lengths of these
paths, from the air inlet opening of the cartridge, through the
cartridge, to the air outlet opening of the cartridge, are
substantially the same. Therefore, all portions of the active
surfaces are exposed to substantially the same amount of air flow,
and problems such as "hot spots" and cell imbalance can be
avoided.
[0031] The configuration and the size of the diffusion tubes help
to keep air flow through the cartridge to a minimum when the blower
30 is off. Each of the diffusion tubes has a cross-sectional area
of about 1 mm.sup.2 to about 8 mm.sup.2 and a length of about 10 mm
to about 70 mm. The diffusion tubes are sized to permit a flow rate
through the cartridge of about less than about 3.46.times.10.sup.-2
L/hour, preferably less than about 3.46.times.10.sup.-3 L/hour,
when the air mover is off. Limited air flow helps to minimize the
self-discharge of the battery and to reduce carbonization of the
electrolyte. It also helps to maintain a constant humidity level in
the cell, and helps to minimize the amount of oxygen and CO.sub.2
entering the cell. Although limited air flow has many advantages,
it is preferred that at least some oxygen remains in the cell. If
the level of oxygen is too low, it can be difficult for the air
mover to switch on after a period of inactivity.
[0032] The metal air cells 6 in the cartridge cooperate to define a
battery that delivers a current of at least 300 mA when the air
mover is on. In some embodiments, the battery delivers a current of
at least 500 mA, 900 mA, 1000 mA, or 1700 mA when the air mover is
on. In other embodiments, the battery has an output current density
of about 1 to about 200 MA/cm.sup.2, for example, about 10 to about
110 mA/cm.sup.2, of air cathode surface when the air mover is
on.
[0033] Referring to FIG. 4, the housing includes a cover 32, a
blower 30, an air outlet opening 33, a pack release button 34, a
cartridge contact 38, and a base 42. The housing 44 for the blower
is built into the pack housing, so there is no need for a separate
case for the blower. The cartridge includes alignment tabs 45 that
help the user position the cartridge in the proper orientation.
[0034] When the voltage drops below a certain level, the blower 30
turns on. When the blower is on, air is moved from the air outlet
opening 33 of the housing to the air inlet opening 46 of the
cartridge. Air moves through the cartridge as described above, then
exits the cartridge through the air outlet opening 48.
[0035] Referring to FIG. 5, the locking tab 50 of the cartridge and
the cartridge release latch 52 of the housing interlock to hold the
cartridge in the housing. The cartridge release latch also serves
the purpose of allowing air to exit the housing.
[0036] When the cells in the cartridge are depleted, the entire
cartridge can be easily removed, then replaced with a fresh
cartridge. The cartridge and the housing are configured to
interlock only when the cartridge is placed in the housing in the
proper position. That is, the cartridge and housing interlock only
when the air inlet opening in the cartridge and the air outlet
opening of the housing align. In addition, the electrical contacts
align in this position. This configuration prevents a consumer from
placing the cartridge in the housing upside-down, or rotated by
180.degree..
[0037] All publications and patents mentioned in this application
are herein incorporated by reference to the same extent as if each
individual publication or patent was specifically and individually
indicated to be incorporated by reference.
[0038] Other embodiments are within the scope of the following
claims.
* * * * *