Abstract: A catalyst composition for use in a rechargeable metal-air electrochemical cell comprises an oxygen evolution catalyst coated with a thin film deposition of a binder and an electrically conductive particulate material which is not corroded during charge. This catalyst is useful to make an air electrode which has greater corrosion protection than an air electrode having an oxygen evolution catalyst without the thin film deposition.

Abstract: An air manager system for a metal-air battery. The system includes a housing for enclosing at least one metal-air cell with an air electrode. The housing also has at least one air inlet opening, at least one air outlet opening, and a fan positioned to force air through the openings when the fan is turned on. These openings are unobstructed and sized to eliminate substantially the air flow through the openings when the fan is turned off. The system also includes fan control means having voltage sensing means to monitor the voltage across the air electrode and to operate the fan when the voltage reaches predetermined levels.

Abstract: A bi-directional air exchanger for a metal-air battery having a housing. The air exchanger includes an ambient air passageway for a first flow of air in a first direction, a battery exhaust passageway for a second flow of air in a second direction, and one or more membranes. The ambient air passageway and the battery exhaust passageway are separated within the housing by the one or more membranes such that the first and the second flows of air are in fluid communication with one another for the exchange of humidity.

Abstract: A ventilation system for one or more metal-air cells includes a distributor for uniformly distributing oxygen between oxygen electrodes in response to operation of an air moving device. The distributor may be further operative, or associated with one or more restrictive passageways that are operative, while unsealed to provided a barrier function that protects the metal-air cells from the ambient environment while the air moving device is not operating. The perforated member defines a plurality of apertures that at least partially define the reactant air flow path through which air is supplied to the metal-air cells. The perforated member may be a plate or an elongate ventilation passageway, such as a tube. The metal-air cells may be arranged in a stack, and a first of the apertures is more proximate to a first plenum defined between the cells than a second plenum defined between the cells, and a second of the apertures is more proximate to the second plenum than the first plenum.

Abstract: A catalyst composition for use in a rechargeable metal-air electrochemical cell comprises an oxygen evolution catalyst coated with a thin film deposition of carbon. This catalyst is useful to make an air electrode which produces more power in a metal-air cell then a metal-air cell having oxygen evolution catalyst without the thin carbon film.

Abstract: Provided are metal-air cells for connecting to one another to form a battery stack. Two or more of the cells are joined by heat or chemical fusing to create the battery stack. Each of the metal-air cells have a case with an exterior surface and an interior surface that defines a chamber that contains an anode and an air cathode. The case defines air openings that extend between the exterior surface and the interior surface for supplying air from the environment exterior to the case to the air cathodes within the chamber. In one embodiment, each metal-air cell includes a plurality of protruding connector members and a plurality of protruding mechanical stops. Two cells are joined by fusing connector members of one cell to connector members of the other cell. During the fusing of the connector members, the mechanical stops of the cells being joined abut one another to arrest movement of the cells toward one another. The arresting causes a plenum to be uniformly defined between the cells.

Abstract: The present invention provides a battery system, a device, and a method to allow multiple batteries with varying capacities and power capabilities to drive a common load. Furthermore, the present invention provides a method for adjusting the output current of one or more of the batteries driving a common load to maximize the operational time of the load. The level of the current being supplied by the battery unit is monitored and compared to a desired current level. Upon detecting a change in the level of the current, the output voltage of one or more of the battery systems is modified to return the level of the battery current to the desired current level. This is accomplished by detecting the battery current (31) with a detector (66) and transforming the change in the battery current into an error signal (76) by comparing a voltage, representative of the battery current (31) with a reference value (72). The error signal (76) is then converted into an output adjust signal (62) by an adjuster (78).

Abstract: A current collector for an electrode with two halves. The current collector has a first layer positioned on the first half of the electrode, a second layer positioned on the second half of said electrode, and a third layer positioned between the first and the second halves of the electrode.

Abstract: A permeable membrane comprising a gas permeable substrate film and a layer of a polymeric perfluoro compound on the substrate exhibits selective transport of oxygen over water vapor and a metal-air electrochemical cell comprising such a membrane has enhanced control over its water content. Suitable polymeric perfluoro compounds include perfluoropolyalkylene oxides such as polyperfluoropropylene oxide or polyperfluoropropylene oxide co-perfluoroformaldehyde. The polymeric perfluoro compound layer is desirably crosslinked to form a thin layer on the substrate film or to form a self-supporting membrane. A suitable substrate film is a microporous polymer membrane.

Abstract: A ventilation system for a metal-air battery having a housing for enclosing at least one metal-air cell. The housing has at least one air inlet opening and at least one air outlet opening. A fan is positioned to force air into the air inlet opening and out of the air outlet opening when the fan is turned on. The openings are sized with a length in the direction through the thickness of the housing being greater than a width in the direction perpendicular to the thickness of the housing. The openings are unobstructed and are sized to eliminate substantially the air flow into the air inlet opening and out of the air outlet opening when the fan is turned off. According to another aspect of the invention, a fan within the battery housing is positioned to distribute air to two separate sets of metal-air cells at the same time.

Abstract: A charging system and method are disclosed that provide balanced charge cycles for batteries or multiple-cell battery packs by using a controller, a charging source gate, multiple adjustable shunting devices and multiple charge monitors. During a virgin charge cycle, the controller adjusts each of the adjustable shunting devices to provide a maximum charging current, opens the charging source gate, and then monitors the charge level of each of the battery cells. When the voltage potential of one of the battery cells reaches a threshold value, the charge source gate is closed to disable the charging current, and the fully charged battery cell is identified. The controller then determines a shunt value for adjusting the adjustable shunting device connected to the fully charged battery cell and uses this shunt value on the next charge cycle. Each subsequent charge cycle results in a different battery cell becoming fully charged and then the recalculation of a shunt value.

Abstract: Provided are metal-air cells that each include a plurality of protruding connector members and a plurality of protruding mechanical stops. Two or more of the cells are joined to create a battery stack. Two cells are joined by heating connector members of the cells, and then forcing the cells together so that the connector members of one cell are welded or fused to connector members of the other cell. During the fusing of the connector members, the mechanical stops of the cells being joined abut one another to arrest movement of the cells toward one another. The arresting causes a plenum to be uniformly defined between the cells. The fused connector members and abutting mechanical stops cooperate to define three-dimensional truss-like system that provides structural integrity. Each of the metal-air cells have a case with an exterior. surface and an interior surface that defines a chamber that contains an anode and air cathodes.

Abstract: A metal-air battery pack is disclosed for external assembly to a portable electronic device with a battery compartment. The battery pack electrically connects to the electronic device through an existing connector of the device that is located in the battery compartment of the device. Another aspect of the present invention provides a palm rest as part of a battery for a portable computing device. Another aspect of the invention provides a network of barriers defining an air pathway through a cathode air plenum to efficiently direct air to the air cathodes of the cells of the battery.

Abstract: A metal-air electrochemical cell comprising an oxygen reservoir disposed in an air plenum adjacent the air cathode. The oxygen reservoir includes an oxygen binding compound characterized in that the oxygen binding compound reversibly binds oxygen and releases oxygen into the air in the air plenum to power the cell when the partial pressure of oxygen in the air plenum drops due to a load on the cell.

Abstract: A rechargeable metal-air battery having a housing, an air flow path, and at least one metal-air cell positioned within the housing. An air movement device communicates with the housing. The metal-air cell generates oxygen and hydrogen during cell charging. The air movement device creates a pulsating air flow within the air flow path for directing a flow of the generated gases.

Abstract: A ventilation system for a metal-air battery having a housing for enclosing at least one metal-air cell. The housing has at least one air inlet opening and at least one air outlet opening. A fan is positioned to force air into the air inlet opening and out of the air outlet opening when the fan is turned on. The openings are sized with a length in the direction through the thickness of the housing being greater than a width in the direction perpendicular to the thickness of the housing. The openings are unobstructed and are sized to eliminate substantially the air flow into the air inlet opening and out of the air outlet opening when the fan is turned off.

Abstract: A metal-air battery pack is disclosed for external assembly to a portable electronic device with a battery compartment. The battery pack electrically connects to the electronic device through an existing connector of the device that is located in the battery compartment of the device. Another aspect of the present invention provides a palm rest as part of a battery for a portable computing device.

Abstract: A dual air electrode metal-air cell having a casing with an upper cathode mask wall, a lower cathode mask wall, and a side wall; an anode assembly having a layer of anode material positioned above and below an anode collector and means, that may be a membrane or a solid foil current collector, for inhibiting movement of anode material between the two layers; separator materials covering the anode assembly on at least its upper and lower sides; an upper air cathode positioned between the upper cathode mask wall and the separator materials on the upper side of the anode assembly; a lower air cathode positioned between the lower cathode mask wall and the separator materials on the lower side of the anode assembly; a gas vent positioned on one or more of the side walls of the casing; and a liquid electrolyte substantially trapped by the separator materials.

Abstract: A dual air electrode metal-air cell having a casing including an upper cathode mask wall, a lower cathode mask wall, and a plurality of side walls; a metal anode with at least upper and lower sides covered with separator materials; an upper air cathode positioned between the upper cathode mask wall and the separator materials on the upper side of the anode; a lower air cathode positioned between the lower cathode mask wall and the separator materials on the lower side of the anode; a gas vent positioned on one or more of the side walls of the casing; and a liquid electrolyte substantially trapped by the separator materials. The separator materials comprise one ore more layers of an absorbent fibrous web and one or more layers of a microporous membrane that, when wet, is gas-impermeable and liquid-permeable.