Abstract: A system for producing metal particles using a discrete particle electrolyzer cathode, a discrete particle electrolyzer cathode, and methods for manufacturing the cathode. The cathode has a plurality of active zones on a surface thereof at least partially immersed in a reaction solution. The active zones are spaced from one another by between about 0.1 mm and about 10 mm, and each has a surface area no less than about 0.02 square mm. The cathode is spaced from an anode also at least partially immersed in the reaction solution. A voltage potential is applied between the anode and cathode. Metal particles form on the active zones of the cathode. The particles may be dislodged from the cathode after they have achieved a desired size. The geometry and composition of the active zones are specified to promote the growth of high quality particles suitable for use in metal/air fuel cells. Cathodes may be formed from bundled wire, machined metal, chemical etching, or chemical vapor deposition techniques.

Abstract: A method of producing metal particles through electrolysis. A cathode having a plurality of active zones on a surface thereof is at least partially immersed in a reaction solution. The cathode is spaced from an anode also at least partially immersed in the reaction solution. A voltage potential is applied between the anode and cathode. Metal particles form on the active zones of the cathode. In order to promote the formation of good quality particles, a turbulent flow of the solution is maintained past one or more the active zones, and the current density in the active zones is maintained greater than about 5 kA/m2. The particles may be dislodged from the cathode after they have achieved a desired size.

Abstract: A method and apparatus for converting single multiphase fluid flow into plural multiphase fluid flows having substantially uniform composition and flow properties. A manifold comprises an enclosure having an inlet and an inner surface perpendicular to the inlet such that the incident angle of input flow impacts the surface to form a stagnation point whereby an intermediate flow is deflected along the surface substantially symmetrically outward from the stagnation point and channeled to a plurality of parallel fluid outlets connected to the enclosure. The distance between the stagnation point and the plurality of outlets is selected to maintain substantially equivalent fluid pressures and uniform flow rates at the outlets. A preferred embodiment of the manifold channels the intermediate flow between two walls forming a triangular shaped nozzle directing the flow from the stagnation point to the base of the triangle for communication of electrolyte to a metal-based fuel cell through the plurality of outlets.

Abstract: A system for filtering particles within a multiphase fluid that comprises a particulate phase is disclosed. The system comprises a first plurality of substantially parallel, substantially planar thin slabs separated by a predetermined distance to retain particles having a maximum cross-sectional dimension greater than the predetermined distance, and provides at least one flow path for at least part of the multiphase fluid. In one application, the system is used in connection with an electrochemical power source and components thereof, wherein the multiphase fluid comprises flowable fuel.

Abstract: A fuel cell system is described which comprises a power source and a fuel storage unit. A flowable fuel is contained with the fuel storage unit. A first flow path delivers fuel from the fuel storage unit to the power source. Some or all of this fuel is deposited into the individual cell cavities within the power source. A second flow path delivers fuel that is not deposited into the cell cavities to the fuel storage unit. A third flow path delivers unused and/or partially used fuel and/or reaction products and/or spent reaction solution from the cell cavities back to an optional reaction product storage unit and/or the fuel storage unit and/or to the second flow path. The system may further comprise an optional reaction product storage unit, an optional regeneration unit, an optional second reactant storage unit, an optional controller, and an optional power converter.

Abstract: A metal-based fuel cell in which a flow path delivers a flow of reaction solution through a particulate anode and one or more particle releasers are situated along the flow path and configured to release from the cell particles which are prone to clogging due to reductions in size caused by anodic dissolution.

Abstract: A system for producing metal particles using a discrete particle electrolyzer cathode, a discrete particle electrolyzer cathode, and methods for manufacturing the cathode. The cathode has a plurality of active zones on a surface thereof at least partially immersed in a reaction solution. The active zones are spaced from one another by between about 0.1 mm and about 10 mm, and each has a surface area no less than about 0.02 square mm. The cathode is spaced from an anode also at least partially immersed in the reaction solution. A voltage potential is applied between the anode and cathode. Metal particles form on the active zones of the cathode. The particles may be dislodged from the cathode after they have achieved a desired size. The geometry and composition of the active zones are specified to promote the growth of high quality particles suitable for use in metal/air fuel cells. Cathodes may be formed from bundled wire, machined metal, chemical etching, or chemical vapor deposition techniques.

Abstract: A method and apparatus for converting single multiphase fluid flow into plural multiphase fluid flows having substantially uniform composition and flow properties. A manifold comprises an enclosure having an inlet and an inner surface perpendicular to the inlet such that the incident angle of input flow impacts the surface to form a stagnation point whereby an intermediate flow is deflected along the surface substantially symmetrically outward from the stagnation point and channeled to a plurality of parallel fluid outlets connected to the enclosure. The distance between the stagnation point and the plurality of outlets is selected to maintain substantially equivalent fluid pressures and uniform flow rates at the outlets. A preferred embodiment of the manifold channels the intermediate flow between two walls forming a triangular shaped nozzle directing the flow from the stagnation point to the base of the triangle for communication of electrolyte to a metal-based fuel cell through the plurality of outlets.

Abstract: Methods of and systems for filtering particles, whose largest cross-sectional dimension is greater than a predetermined distance, of a multiphase fluid that comprises a particulate phase are provided. The methods provide for a step for delivering the multiphase flowable fuel through filter means, wherein the filter means is for retaining particles of the particulate phase whose largest cross-sectional dimension is greater than a predetermined distance. The systems provide for means for retaining particles whose largest cross-sectional dimension is greater than a predetermined distance, and means for providing at least one flow path for at least part of the multiphase fluid. In one application, the methods and systems are used in connection with an electrochemical power source and components thereof.

Abstract: A method and apparatus for converting single multiphase fluid flow into plural multiphase fluid flows having substantially uniform composition and flow properties. A manifold comprises an enclosure having an inlet and an inner surface perpendicular to the inlet such that the incident angle of input flow impacts the surface to form a stagnation point whereby an intermediate flow is deflected along the surface substantially symmetrically outward from the stagnation point and channeled to a plurality of parallel fluid outlets connected to the enclosure. The distance between the stagnation point and the plurality of outlets is selected to maintain substantially equivalent fluid pressures and uniform flow rates at the outlets. A preferred embodiment of the manifold channels the intermediate flow between two walls forming a triangular shaped nozzle directing the flow from the stagnation point to the base of the triangle for communication of electrolyte to a metal-based fuel cell through the plurality of outlets.

Abstract: A packed bed static mixer, and a piping network including the same, is disclosed. The packed bed static mixer includes a vertical intake portion, within which packing material consisting of small elements, is disposed. The packing elements may be spheres, PALL RING elements, or the like, and are fabricated of a material suitable for the particular application of the static mixer. The size of the packing elements is maintained to be relatively small relative to the mixer, to provide numerous mixing vortices therewithin; the packing elements are randomly packed into the static mixer. Outlets are provided which extend horizontally and radially from the bottom of the static mixer, and are typically of smaller diameter than the intake portion. Because the mixing action depends upon the size of the vortices at the interstitial voids among the packing elements, the disclosed static mixer design may be readily scaled to various diameters.