Abstract: A ventilation system for a metal-air battery is disclosed. The metal-air battery has one or more air cathodes, one or more air pathways from the air cathode to a reactive gas source, a closure member associated with each of the air pathways to selectively prevent the flow of gas through the air pathways and one or more volume-changeable plenums in fluid communication with the air pathway and the air cathode. When the battery is not in use, the closure member is closed and the door is closed to save the battery life time. When the battery is activated, the air pathway is opened and the volume of the plenum is increased to introduce fresh air from the outside to the plenum. A method of producing electricity using a metal-air battery is also disclosed.

Abstract: A ventilation system for metal-air battery cells having collapsible isolation passageways for controlling ambient airflow to the oxygen electrode of the metal-air battery. The ventilation system has at least one inlet isolation passageway and at least one outlet isolation passageway. The isolation passageways normally remain in a collapsed position to restrict airflow when an air mover is turned off. The isolation passageways may be configured into an expanded position in response to airflow generated by the air mover. In the expanded position, the inlet isolation passageway permits ambient air to flow across the oxygen electrode and the outlet isolation passageway permits oxygen depleted air to be expelled.

Abstract: A metal-air battery with an air moving device controller to determine when a load is present on the battery and the extent of that load is described. The air moving device controller allows the operation of the air moving device for the battery to be responsive to the load. Advantageously, the controller allows the metal-air battery to limit the intake of oxygen and other gases to that amount needed to drive the load.

Abstract: A bifunctional air electrode for a rechargeable metal-air cell is made with water soluble oxygen reduction and oxygen evolution catalyst precursors. The resulting air electrode exhibits greater power output than a conventional air electrode.

Abstract: A cylindrical metal-air cell has a cylindrical housing, an axially extending cylindrical air cathode adjacent an interior surface of the housing, and a plurality of elongate plenums defined between the oxygen electrode and the interior surface of the housing. Isolating passageway are positioned between the ambient environment and each of the plenums, and an air moving device is operable to force air through the isolating passageways and into at least one of the plenums. The air moving device may be a micromachined blower controlled by a circuit integrated into the housing of the blower.

Abstract: A metal-air cell with an anode container. The anode container is made from a reactive metal. The metal-air cell also has an absorbent layer with a first side and a second side. An electrolyte is substantially trapped within the absorbent layer. The first side of the absorbent layer is positioned in contact with the anode container and an air electrode is positioned in contact with the second side of the absorbent layer.

Abstract: Methods and apparatus are disclosed for three-dimensional flight control based generally upon measuring and comparing actual air pressures at or near various surfaces of an aircraft during flight. Sensors are provided for measuring air pressure acting on an aircraft surface. The methods and apparatus include those for measuring air pressure differentials between two or more sensors to evaluate certain critical flight parameters, such as the actual lift being produced, the air direction and speed relative to the aircraft, the air density, and the aircraft position and trajectory. The actual and comparative data provide information about the present flight conditions and performance of the aircraft, such as whether there is ice formed or forming on the wings, the direction and approach of wind shear, whether a stall is approaching, etc.

Abstract: A primary metal-air power source containing one or more metal-air cells incorporating an air manager in a power source housing of the power source. The power source provides intermittent use at high power levels over a long lifetime while demonstrating a high utilization of the metal, such as zinc, making up the metal-air cell's metal anode. The power source provides 80% of its amp hour capacity for at least 30 days after the initial partial discharge at a power level of at least 50 milliwatts. The cumulative run time may comprise any number of intermittent connections to a load having varying duration. The ventilation system of the power source draws ambient airflow through an isolating passageway by operating an air mover which distributes the airflow to the metal-air cells.

Abstract: A cylindrical metal-air cell has a cylindrical housing, an axially extending cylindrical air cathode adjacent an interior surface of the housing, and a plurality of elongate plenums defined between the oxygen electrode and the interior surface of the housing. Isolating passageway are positioned between the ambient environment and each of the plenums, and an air moving device is operable to force air through the isolating passageways and into at least one of the plenums. The air moving device may be a micromachined blower controlled by a circuit integrated into the housing of the blower.

Abstract: An improved metal-air battery having a metal-air cell stack positioned within a substantially uniform shell. The metal-air cell stack includes an isolating passageway and a substantially oxygen-permeable, water impermeable shell.

Abstract: An anode for use in an electrochemical cell comprises a plate of non-particulate, mercury-free zinc metal and a coating of indium metal on at least a portion of the zinc plate surface. The anode is particularly useful in a rechargeable metal-air cell. The elimination of mercury enhances the safety of the cell and the indium coating reduces gassing at the anode and corrosion of the anode. Desirably, the electrolyte in the metal air cell also includes indium hydroxide. Also, a method for making the anode using a hot-plate joining process.

Abstract: An air-managing system for metal-air battery includes resealable septum and one or more hollow needles. The septum separates air pathway into two segments. One segment is from air cathodes of the battery to the septum and the other is from the septum to the outside air. The needles provide conduits to connect two segments. The septum re-closes its torn portion when the needles are removed. Also disclosed is a reusable air manager including a fan and such needles. The air manager can be coupled to a disposable cell pack which has a septum that can be pierced by the needles.

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 method and apparatus for measuring the lift generated by airfoils of an aircraft. This real-time analysis is accomplished by measuring a differential pressure between the upper and lower lift surfaces of the airfoils. The system comprises the steps of: a) measuring an actual differential pressure between the upper and lower lift surfaces for a given aircraft speed, b) transmitting this actual differential pressure measurement to a computer, c) comparing the actual differential pressure measurement with an optimal pressure differential for the same aircraft speed. The apparatus comprises a fixed array of differential pressure sensor mechanisms for measuring actual pressure differentials and a computer for comparing optimal differential pressure measurements to the actual differential pressure measurements. Each sensor mechanism preferably contains a piezoelectric sensor that communicates with the upper and lower lift surfaces.