Patents Assigned to PowerGenix Systems, Inc.
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Patent number: 9337483Abstract: A pasted positive nickel hydroxide electrode for use in battery cells (e.g., in nickel zinc cells, and nickel metal hydride cells) includes nickel hydroxide particles, a cobalt metal and/or cobalt compound and a sulfur-containing complexing agent capable of forming a complex with cobalt. The presence of the sulfur-containing complexing agent, such as dialkyldithiocarbamate (e.g., sodium diethyldithiocarbamate) improves lifetime and capacity utilization of the nickel electrode. The resulting pasted nickel hydroxide electrode includes a CoOOH conductive matrix after formation. The surface of the nickel hydroxide particles in the electrode is modified in some embodiments by providing a cobalt-containing coating onto the surface of the nickel hydroxide particles, followed by oxidation with a strong oxidizing agent. The complexing agent can be added before, after, or during the oxidation.Type: GrantFiled: January 8, 2014Date of Patent: May 10, 2016Assignee: PowerGenix Systems, Inc.Inventor: Mingming Geng
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Patent number: 9337683Abstract: A control system is designed or configured to control the state of charge of a battery or battery pack in a system containing a separate power source, which is separate from the battery or battery pack. In operation, the battery or battery pack is called upon to intermittently provide power for certain functions. The separate power source may be, for example, an AC electrical power source for a UPS or an engine of a vehicle such as a micro hybrid vehicle. The battery may be a nickel zinc aqueous battery. The control system may be designed or configured to implement one or more of the following functions: monitoring the state of charge of the battery or battery pack; directing rapid recharge of the battery or battery pack from the separate power source when the battery or battery pack is not performing its functions; and directing charge to fully charged level or a float charge level, which is different from the fully charged level, in response to operating conditions.Type: GrantFiled: December 20, 2012Date of Patent: May 10, 2016Assignee: PowerGenix Systems, Inc.Inventors: Jeffrey Phillips, Salil Soman
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Patent number: 9048488Abstract: Active material for a negative electrode of a rechargeable zinc alkaline electrochemical cell is made with zinc metal particles coated with tin and/or lead. The zinc particles may be coated by adding lead and tin salts to a slurry containing zinc particles, a thickening agent and water. The remaining zinc electrode constituents such as zinc oxide (ZnO), bismuth oxide (Bi2O3), a dispersing agent, and a binding agent such as Teflon are then added. The resulting slurry/paste has a stable viscosity and is easy to work with during manufacture of the zinc electrode. Further, the zinc electrode is much less prone to gassing when cobalt is present in the electrolyte. Cells manufactured from electrodes produced in accordance with this invention exhibit much less hydrogen gassing, by as much as 60-80%, than conventional cells. The cycle life and shelf life of the cells is also enhanced, as the zinc conductive matrix remains intact and shelf discharge is reduced.Type: GrantFiled: July 10, 2013Date of Patent: June 2, 2015Assignee: PowerGenix Systems, Inc.Inventors: Jeffrey Phillips, Samaresh Mohanta, Cecelia Maske, Deepan Chakkaravarthi Bose, James J. Wu, Bryan L. McKinney
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Patent number: 8940430Abstract: A nickel zinc battery cell includes a metallic zinc-based current collection substrate as a part of the negative electrode. The metallic zinc-based current collector may be made of or be coated with a zinc metal or zinc alloy material and may be a foil, perforated, or expanded material. Battery cells incorporating the zinc-based current collector exhibit good cycle lifetime and initial charge performance.Type: GrantFiled: February 8, 2008Date of Patent: January 27, 2015Assignee: PowerGenix Systems, Inc.Inventors: Jeffrey Phillips, Samaresh Mohanta, Zhen Gang Fan, Ru Jun Ma, Feng Feng, Lou Uzel, Chi Yau, Jason Zhao, Zeiad M. Muntasser
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Publication number: 20140199591Abstract: A pasted positive nickel hydroxide electrode for use in battery cells (e.g., in nickel zinc cells, and nickel metal hydride cells) includes nickel hydroxide particles, a cobalt metal and/or cobalt compound and a sulfur-containing complexing agent capable of forming a complex with cobalt. The presence of the sulfur-containing complexing agent, such as dialkyldithiocarbamate (e.g., sodium diethyldithiocarbamate) improves lifetime and capacity utilization of the nickel electrode. The resulting pasted nickel hydroxide electrode includes a CoOOH conductive matrix after formation. The surface of the nickel hydroxide particles in the electrode is modified in some embodiments by providing a cobalt-containing coating onto the surface of the nickel hydroxide particles, followed by oxidation with a strong oxidizing agent. The complexing agent can be added before, after, or during the oxidation.Type: ApplicationFiled: January 8, 2014Publication date: July 17, 2014Applicant: PowerGenix Systems, Inc.Inventor: Mingming Geng
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Publication number: 20140175869Abstract: A control system is designed or configured to control the state of charge of a battery or battery pack in a system containing a separate power source, which is separate from the battery or battery pack. In operation, the battery or battery pack is called upon to intermittently provide power for certain functions. The separate power source may be, for example, an AC electrical power source for a UPS or an engine of a vehicle such as a micro hybrid vehicle. The battery may be a nickel zinc aqueous battery. The control system may be designed or configured to implement one or more of the following functions: monitoring the state of charge of the battery or battery pack; directing rapid recharge of the battery or battery pack from the separate power source when the battery or battery pack is not performing its functions; and directing charge to fully charged level or a float charge level, which is different from the fully charged level, in response to operating conditions.Type: ApplicationFiled: December 20, 2012Publication date: June 26, 2014Applicant: PowerGenix Systems, Inc.Inventors: Jeffrey Phillips, Salil Soman
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Patent number: 8703330Abstract: Nickel zinc cylindrical battery cell designs are described. The designs provided limit dendrite formation and prevent build up of hydrogen gas in the cell. The present invention also provides low-impedance cells required by rapid discharge applications. The cylindrical battery cells may have polarity opposite of that of conventional power cells, with a negative cap and positive can. The cylindrical cells may include a gel electrolyte reservoir.Type: GrantFiled: April 26, 2005Date of Patent: April 22, 2014Assignee: PowerGenix Systems, Inc.Inventors: Jeffrey Phillips, Samaresh Mohanta, Zheng Gang Fan, Chi Wang Yau, Lou Ludek Uzel
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Patent number: 8597379Abstract: Embodiments are described in terms of selective methods of sealing separators and jellyroll electrode assemblies and cells made using such methods. More particularly, methods of selectively heat sealing separators to encapsulate one of two electrodes for nickel-zinc rechargeable cells having jellyroll assemblies are described. Selective heat sealing may be applied to both ends of a jellyroll electrode assembly in order to selectively seal one of two electrodes on each end of the jellyroll.Type: GrantFiled: July 13, 2012Date of Patent: December 3, 2013Assignee: PowerGenix Systems, Inc.Inventors: Bryan L. McKinney, Steve Salamon, James Wu, Todd F. Tatar, Brian M. Schroeter, Jeffrey Phillips
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Patent number: 8501351Abstract: Active material for a negative electrode of a rechargeable zinc alkaline electrochemical cell is made with zinc metal particles coated with tin and/or lead. The zinc particles may be coated by adding lead and tin salts to a slurry containing zinc particles, a thickening agent and water. The remaining zinc electrode constituents such as zinc oxide (ZnO), bismuth oxide (Bi2O3), a dispersing agent, and a binding agent such as Teflon are then added. The resulting slurry/paste has a stable viscosity and is easy to work with during manufacture of the zinc electrode. Further, the zinc electrode is much less prone to gassing when cobalt is present in the electrolyte. Cells manufactured from electrodes produced in accordance with this invention exhibit much less hydrogen gassing, by as much as 60-80%, than conventional cells. The cycle life and shelf life of the cells is also enhanced, as the zinc conductive matrix remains intact and shelf discharge is reduced.Type: GrantFiled: May 18, 2009Date of Patent: August 6, 2013Assignee: PowerGenix Systems, Inc.Inventors: Jeffrey Phillips, Samaresh Mohanta, Cecilia Maske, Deepan Chakkaravarthi Bose, James J. Wu, Bryan L. McKinney
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Patent number: 8372542Abstract: An improved Ni—Zn cell with a negative electrode substrate plated with tin or tin and zinc during manufacturing has a reduced gassing rate. The copper or brass substrate is electrolytic cleaned, activated, electroplated with a matte surface to a defined thickness range, pasted with zinc oxide electrochemically active material, and baked. The defined plating thickness range of 40-80 ?In maximizes formation of an intermetallic compound Cu3Sn that helps to suppress the copper diffusion from under plating layer to the surface and eliminates formation of an intermetallic compound Cu6Sn5 during baking to provide adequate corrosion resistance during battery operation.Type: GrantFiled: April 20, 2012Date of Patent: February 12, 2013Assignee: PowerGenix Systems, Inc.Inventors: Feng Feng, Jeffrey Phillips, Samaresh Mohanta, Jeff Barton, Zeiad M. Muntasser
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Publication number: 20120205248Abstract: An improved Ni—Zn cell with a negative electrode substrate plated with tin or tin and zinc during manufacturing has a reduced gassing rate. The copper or brass substrate is electrolytic cleaned, activated, electroplated with a matte surface to a defined thickness range, pasted with zinc oxide electrochemically active material, and baked. The defined plating thickness range of 40-80 ?In maximizes formation of an intermetallic compound Cu3Sn that helps to suppress the copper diffusion from under plating layer to the surface and eliminates formation of an intermetallic compound Cu6Sn5 during baking to provide adequate corrosion resistance during battery operation.Type: ApplicationFiled: April 20, 2012Publication date: August 16, 2012Applicant: PowerGenix Systems, Inc.Inventors: Feng Feng, Jeffrey Phillips, Sam Mohanta, Jeff Barton, Zeiad M. Muntasser
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Patent number: 8182946Abstract: An improved Ni—Zn cell with a negative electrode substrate plated with tin or tin and zinc during manufacturing has a reduced gassing rate. The copper or brass substrate is electrolytic cleaned, activated, electroplated with a matte surface to a defined thickness range, pasted with zinc oxide electrochemically active material, and baked. The defined plating thickness range of 40-80 ?In maximizes formation of an intermetallic compound Cu3Sn that helps to suppress the copper diffusion from under plating layer to the surface and eliminates formation of an intermetallic compound Cu6Sn5 during baking to provide adequate corrosion resistance during battery operation.Type: GrantFiled: March 23, 2011Date of Patent: May 22, 2012Assignee: Powergenix Systems, Inc.Inventors: Feng Feng, Jeffrey Phillips, Samaresh Mohanta, Jeff Barton, Zeiad M. Muntasser
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Patent number: 8048566Abstract: The nickel hydroxide particles for a nickel hydroxide electrode may be treated using an alkaline solution of a strong oxidizing agent such as sodium or potassium persulfate to modify the surface nickel hydroxide structure. The resulting modified surface structure has been found to impart various benefits to electrodes formed from the nickel hydroxide. It is believed that the oxidation of cobalt compounds at the surface of the nickel hydroxide particles results in a highly conductive cobalt compound that plays an important role in the high reliability, high stability and high capacity utilization of nickel electrodes as described herein.Type: GrantFiled: April 29, 2009Date of Patent: November 1, 2011Assignee: Powergenix Systems, Inc.Inventors: Mingming Geng, Jeffrey Phillips, Samaresh Mohanta
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Patent number: 8048558Abstract: A nickel-zinc battery cell is formed with a negative can, a positive cap, and a jelly roll of electrochemically active positive and negative materials within. The inner surface of the can is protected with an anticorrosive material that may be coated or plated onto the can. Good electrical contact between the jelly roll and the cap is achieved through folding the nickel substrate over to contact a positive current collection disk.Type: GrantFiled: March 25, 2009Date of Patent: November 1, 2011Assignee: PowerGenix Systems, Inc.Inventors: Jeffrey Phillips, Franz Josef Kruger, Samaresh Mohanta, Sean Clinton, Ernest M. Rimanosky, Jason Zhao, Cecilia Maske, Zheng Gang Fan
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Patent number: 8043748Abstract: Active material for a positive electrode of a rechargeable alkaline electrochemical cell is made with nickel hydroxide particles or cobalt-coated nickel hydroxide particles treated with strongly oxidizing reagents such as alkali metal persulfate in alkaline solution. The active material also may be made with cobalt-coated nickel hydroxide particles having a high percentage of cobalt(III) on a surface or an average cobalt oxidation state of about 3 measured across the particles. The treated nickel hydroxide or cobalt-coated nickel hydroxide decreases the cobalt solubility in the alkaline electrolyte and increases the high-rate charge and discharge capability. The lower cobalt solubility decreases cobalt migration that can increase self discharge and lead to premature failure.Type: GrantFiled: February 4, 2009Date of Patent: October 25, 2011Assignee: PowerGenix Systems, Inc.Inventors: Mingming Geng, Samaresh Mohanta, Jeffrey Phillips, Zeiad M. Muntasser, Jeff Barton
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Patent number: 7931988Abstract: An improved Ni—Zn cell with a negative electrode substrate plated with tin or tin and zinc during manufacturing has a reduced gassing rate. The copper or brass substrate is electrolytic cleaned, activated, electroplated with a matte surface to a defined thickness range, pasted with zinc oxide electrochemically active material, and baked. The defined plating thickness range of 40-80 ?In maximizes formation of an intermetallic compound Cu3Sn that helps to suppress the copper diffusion from under plating layer to the surface and eliminates formation of an intermetallic compound Cu6Sn5 during baking to provide adequate corrosion resistance during battery operation.Type: GrantFiled: October 5, 2007Date of Patent: April 26, 2011Assignee: Powergenix Systems, Inc.Inventors: Feng Feng, Jeffrey Phillips, Samaresh Mohanta, Jeff Barton, Zeiad M. Muntasser
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Publication number: 20100291439Abstract: Active material for a negative electrode of a rechargeable zinc alkaline electrochemical cell is made with zinc metal particles coated with tin and/or lead. The zinc particles may be coated by adding lead and tin salts to a slurry containing zinc particles, a thickening agent and water. The remaining zinc electrode constituents such as zinc oxide (ZnO), bismuth oxide (Bi2O3), a dispersing agent, and a binding agent such as Teflon are then added. The resulting slurry/paste has a stable viscosity and is easy to work with during manufacture of the zinc electrode. Further, the zinc electrode is much less prone to gassing when cobalt is present in the electrolyte. Cells manufactured from electrodes produced in accordance with this invention exhibit much less hydrogen gassing, by as much as 60-80%, than conventional cells. The cycle life and shelf life of the cells is also enhanced, as the zinc conductive matrix remains intact and shelf discharge is reduced.Type: ApplicationFiled: May 18, 2009Publication date: November 18, 2010Applicant: PowerGenix Systems, Inc.Inventors: Jeffrey Phillips, Samaresh Mohanta, Cecilia Maske, Deepan Chakkaravarthi Bose, James J. Wu, Bryan L. McKinney
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Patent number: 7833663Abstract: Methods of manufacturing a rechargeable power cell are described. Methods include providing a slurry or paste of negative electrode materials having low toxicity and including dispersants to prevent the agglomeration of particles that may adversely affect the performance of power cells. The methods utilize semi-permeable sheets to separate the electrodes and minimize formation of dendrites; and further provide electrode specific electrolyte to achieve efficient electrochemistry and to further discourage dendritic growth in the cell. The negative electrode materials may be comprised of zinc and zinc compounds. Zinc and zinc compounds are notably less toxic than the cadmium used in NiCad batteries. The described methods may utilize some production techniques employed in existing NiCad production lines. Thus, the methods described will find particular use in an already well-defined and mature manufacturing base.Type: GrantFiled: August 17, 2004Date of Patent: November 16, 2010Assignee: Powergenix Systems, Inc.Inventors: Jeffrey Phillips, Jason Zhao
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Patent number: 7829221Abstract: A nickel-zinc galvanic cell is provided, having a zinc oxide negative electrode, a nickel oxide positive electrode, and an alkaline electrolyte. Chemical additives are placed in each of the negative and positive electrodes. The positive nickel hydroxide electrode contains a mixture of cobalt oxide contained within a nickel oxide matrix in the range of about 1% to 10%, and cobalt metal in the range of about 1% to 10%, by weight. The negative zinc oxide electrode may contain oxides other than the oxide of zinc, which have redox potentials which are negative of ?0.73 volts. Also, the metal oxide additives to the negative zinc oxide electrode are such as to inhibit release of soluble cobalt from the nickel oxide negative electrode prior to a formation charge being applied to the electrochemical cell.Type: GrantFiled: July 26, 2004Date of Patent: November 9, 2010Assignee: PowerGenix Systems, Inc.Inventor: Jeffrey Phillips
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Patent number: 7816030Abstract: Electrodes and electrolytes for nickel-zinc secondary battery cells possess compositions that limit dendrite formation and other forms of material redistribution in the zinc electrode. In addition, the electrolytes may possess one or more of the following characteristics: good performance at low temperatures, long cycle life, low impedance and suitability for high rate applications.Type: GrantFiled: June 1, 2009Date of Patent: October 19, 2010Assignee: Powergenix Systems, Inc.Inventors: Jeffrey Phillips, Samaresh Mohanta