Abstract: A rechargeable electrochemical cell system is provided. The system includes a plurality of cells, wherein each cell is comprised of a first electrode, a second electrode, and a third electrode electrically isolated from the second electrode. The cell system may be discharged upon application of a load across a discharge circuit, which is formed from the first electrodes and the second electrodes. The cell may be recharged upon application of a voltage across a recharging circuit, which is formed of at least one of the first electrodes and at least one of the third electrodes.

Abstract: An electrode for an electrochemical cell is provided. The electrode comprises a plurality of fibers comprised of an electrically conductive material configured to conduct electrons to an electrolyte of the electrochemical cell.

Abstract: A refuelable anode structure containing anode paste for a metal air electrochemical cell is provided. The anode paste comprises metal particles, a gelling agent, and a base. The spent anode structure may be removed after discharging. The anode structure may thereafter be electrically recharged to convert oxidized metal into consumable metal fuel, or mechanically emptied and refilled with fresh metal fuel paste.

Abstract: A metal-air fuel cell battery (FCB) system includes an electrolyte, air electrodes, and a movable anode having anode material deposited on two sides of an electrically conductive substrate. The anode can be, for example, either a rotating anode disk, or a linearly-movable anode, sandwiched between the two air electrodes. The air electrodes each have at least one recharging portion and at least one discharging portion. The anode movement, which can be, for example, rotational or linear, is relative to the recharging air electrode portion for recharging the anode material and relative to the discharging air electrode portion for discharging the anode material.

Abstract: A novel segmented air cathode device of unitary construction for use in a metal-air fuel cell battery system. The device includes a plurality of cells formed by a cathode structure having a plurality of cathode elements on a unitary cathode support structure, and an anode structure having one or more anode-contacting elements on an anode-contacting element support plate. Preferably, the cathode elements include cathode elements of different types. In one embodiment, the device includes first-type cathode elements and corresponding cells optimized for discharging operations and second-type cathode elements and corresponding cells optimized for recharging operations. In an alternate embodiment, the device includes first-type cathode elements and corresponding cells optimized for low-power discharging operations and, second-type cathode elements and corresponding cells optimized for high-power discharging operations. Preferably, each cell can be independently, activated (i.e.

Abstract: Rechargeable electrochemical cells that employ a highly conductive polymer-based solid gel membrane separator disposed between the anode and charging electrode are disclosed. The separator comprises a support or substrate and a polymeric gel composition having an ionic species contained in a solution phase thereof. In preparing the separator, the ionic species is added to a monomer solution prior to polymerization and remains embedded in the resulting polymer gel after polymerization. The ionic species behaves like a liquid electrolyte, while at the same time, the polymer-based solid gel membrane provides a smooth impenetrable surface that allows the exchange of ions for both discharging and charging of the cell. Advantageously, the separator reduces dendrite penetration and prevents the diffusion of reaction products such as metal oxide to remaining parts of the cell.

Abstract: In an air-metal fuel cell battery (FCB) system, wherein a movable cathode structure is mounted within a housing through which metal-fuel tape is transported along a predetermined path while an ionically-conductive medium is disposed between the metal-fuel tape and the movable cathode structure. In illustrative embodiments, the movable cathode structure is realized as a rotatable cathode cylinder, and a transportable cathode belt. The ionically-conductive medium is realized as a solid-state ionically-conductive film applied to the cathode structures and/or metal-fuel tape, as well as ionically-conductive belt structures.

Abstract: A recyclable fuel distribution system comprising a hierarchy of operatively linked (with fuel supply and reaction product collection elements) fluid fuel transport vehicles, fluid fuel storage tanks, fuel supply reservoirs (optional depending on specific use), and fluid fuel usage devices operatively linked to the storage tanks or supply reservoirs, as applicable. The fuel, during use, undergoes a reversible chemical reaction, whereby collected reaction product is reversible to the original fuel. At least one and preferably all of the vehicles, storage tanks and reservoirs contain a storage volume with separated chambers, adapted to inversely change relative to fuel being supplied and reaction product being collected and stored. As a result, a single volume during transport, storage, and use, provides the dual function of fuel supply and collection of reversible reaction product, with concomitant nearly halving of transport, storage and use volumes and costs.

Abstract: Improved electro-chemical power generation devices (e.g., metal-air fuel cell battery devices) having metal-fuel realized in the form of a metal-fuel card including a plurality of electrically-isolated metal-fuel elements (e.g., strips) disposed on the surface of substantially rigid and planar non-electrically-conductive substrate. The metal-fuel elements are in electrical contact with the anode contacting elements of the power generation device when the metal-fuel card is spatially registered to anode contacting elements of the electro-chemical power generation device. In another aspect of the present invention, an aperture formed in the substrate provides electrical contact between the metal-fuel element disposed on the first side of the substrate and the anode contacting element disposed on the second side of the substrate when the metal-fuel card is spatially registered to the anode contacting element.

Abstract: An air depolarized cell with at least one movable cathode element disposed in an active anode metal material which is in a fluid or paste state. The cathode element(s) continuously moves to maintain electrochemical proximity with active anode material as the active anode material is converted into electrochemical cell reaction product. In one embodiment, formation of cell reaction products of increased volume relative to initial anode volume serves to propel the movable cathode through the anode material. Viscosity of the fluid or anode paste is adjusted to ensure cathode movement relative to active anode for maximized utilization.

Abstract: An electrochemical cathode includes a porous metal foam substrate, formed with a network of interconnected pores. An active layer and a hydrophobic microporous gas diffusion layer are both disposed on one or more surfaces of the metal foam substrate. The metal foam substrate serves as the current collector of the cathode. The microporous layer is a plastic material such as a fluoropolymer (i.e., PTFE). The cathode also includes a particulate microstructure reinforced by relatively strong bonding provided by sintering a polymeric binder within the three-dimensional interconnected porosity of the metal foam substrate. The reactive layers are preferably fabricated from the same material as binder. This advantageously enables a single roll pressing operation to simultaneously impregnate the binder into the substrate and form the reactive layers thereon.

Abstract: In an air-metal fuel cell battery (FCB) system, wherein metal-fuel tape, the ionically-conductive medium and the cathode structures are transported at substantially the same velocity at the locus of points at which the ionically-conductive medium contacts the moving cathode structure and the moving metal-fuel tape during discharging and recharging modes of operation. In a first generalized embodiment of the present invention, the ionically-conductive medium is realized as an ionically-conductive belt, and the metal-fuel tape, ionically-conductive belt, and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing belt contacts the metal-fuel tape and the cathode structure during system operation. In a second generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state (e.g.

Abstract: Rechargeable electrochemical cells that employ a highly conductive polymer-based solid gel membrane separator disposed between the anode and charging electrode are disclosed. The separator comprises a support or substrate and a polymeric gel composition having an ionic species contained in a solution phase thereof. In preparing the separator, the ionic species is added to a monomer solution prior to polymerization and remains embedded in the resulting polymer gel after polymerization. The ionic species behaves like a liquid electrolyte, while at the same time, the polymer-based solid gel membrane provides a smooth impenetrable surface that allows the exchange of ions for both discharging and charging of the cell. Advantageously, the separator reduces dendrite penetration and prevents the diffusion of reaction products such as metal oxide to remaining parts of the cell.

Abstract: Disclosed is a method and apparatus for extending path-length of metal-fuel tape during discharging and/or recharging operations so that a supply of metal-fuel tape contained within a cassette device or on a supply reel can be rapidly discharged and/or recharged in an improved manner. During discharging operations, a plurality of discharging heads are selectively arranged about the extended path-length of metal-fuel tape so as increase the rate at which electrical power is powered from the system. During recharging operations, a plurality of recharging heads are selectively arranged about the extended path-length of metal-fuel tape to decrease the time required to recharge the metal-fuel tape transported through the system.

Abstract: An improved metal-air fuel cell battery (FCB) system and a method of producing and supplying electrical power to an electrical power consuming device. The method involves packaging and distributing together (i) a metal-air FCB module for producing electrical power using a metal-fuel card insertable within the metal-air FCB module, and (ii) a supply of metal-fuel cards, available as metal-fuel consumable within the metal-air FCB module. The metal-air FCB module includes a cathode structure and an anode contacting structure wherebetween a metal-fuel card can be inserted during a metal-fuel card loading operation, when electrical power is required from the metal-air FCB module. By virtue of the present invention, consumers can now quickly and easily refuel a metal-air FCB module used to power electrical power consuming devices, without wasting or otherwise replacing the typically massive, expensive, and non-consumed components of the metal-air FCB module.

Abstract: In an air-metal fuel cell battery (FCB) system, wherein a plurality of movable cathode structures are mounted within a compact housing through which metal-fuel tape is transported along a predetermined path while an ionically-conductive medium is disposed between the metal-fuel tape and each movable cathode structure at points of contact. In illustrative embodiments, the movable cathode structures are realized as rotatable cathode cylinders, and transportable cathode belts. The ionically-conductive medium is realized as a solid-state ionically-conductive film applied to the cathode structures and/or metal-fuel tape, as well as ionically-conductive belt structures transported at the same velocity as corresponding cathode structures (e.g. cathode cylinders or belts) at the locus of points at which the ionically-conductive medium contacts the moving cathode structure and the moving metal-fuel tape.

Abstract: Improved metal-air fuel cell battery systems having metal-fuel realized in the form of substantially planar metal-fuel cards of rigid construction, which can be either manually or automatically inserted within the power generation bay of the system. The power generation bay includes at least one electrically-conductive cathode element supported by a cathode support structure in a stationary position with respect to the cathode support structure, and at least one electrically-conductive anode-contacting element supported by an anode contacting structure in a stationary position with respect to the anode contacting structure. In order to produce a range of output voltages, the power generation bay includes a plurality of cells comprising cathode elements spatially arranged with anode contacting elements, and each metal-fuel card has a plurality of electrically-isolated metal-fuel strips that are spatially arranged with these cells when the metal-fuel card is inserted to the power generation bay.

Abstract: Disclosed are various types of metal-air FCB-based systems comprising a Metal-Fuel Transport Subsystem, a Metal-Fuel Discharging Subsystem, and a Metal-Fuel Recharging Subsystem. The function of the Metal-Fuel Transport Subsystem is to transport metal-fuel cards or sheets to the Metal-Fuel Discharge Subsystem, or the Metal-Fuel Recharge Subsystem, depending on the mode of the system selected. When transported to or through the Metal-Fuel Discharge Subsystem, each metal-fuel card is discharged by (i.e. electro-chemically reaction with) one or more discharging heads in order produce electrical power across an electrical load connected to the subsystem while H2O and O2 are consumed at the cathode-electrolyte interface during the electro-chemical reaction.

Abstract: A fuel cell battery having an electrolyte, and a moving anode having anode material deposited on two sides of an electrically conductive substrate, which can be either a rotating anode disk, or a linearly moving anode, sandwiched between two air electrodes wherein the air electrodes each have at least one recharging portion and at least one discharging portion. The recharging portion of the air electrode is designed for optimum recharging and the discharging portion of the air electrode is designed for optimum discharging such that the fuel cell battery performs to its maximum ability. The recharging air electrode area can be larger than the discharging air electrode area for faster recharge times. The recharging air electrode can be operated at lower current densities to prevent anode densification, anode shape change and dendrite growth. Discharging the anode material on both sides of the anode increases the depth of the discharge and increases the battery's capacity.

Abstract: In an air-metal fuel cell battery (FCB) system, wherein metal-fuel tape, the ionically-conductive medium and the cathode structures are transported at substantially the same velocity at the locus of points at which the ionically-conductive medium contacts the moving cathode structure and the moving metal-fuel tape during discharging and recharging modes of operation. In a first generalized embodiment of the present invention, the ionically-conductive medium is realized as an ionically-conductive belt, and the metal-fuel tape, ionically-conductive belt, and movable cathode structure are transported at substantially the same velocity at the locus of points which the ionically-conducing belt contacts the metal-fuel tape and the cathode structure during system operation. In a second generalized embodiment of the present invention, the ionically-conductive medium is realized as a solid-state film layer integrated with the metal-fuel tape.