Abstract: A highly conductive polymer based solid gel membrane is disclosed. The membrane is especially well suited for use in such electrochemical devices as, for example, aluminum/air, zinc/air, Zn/MnO2, Ni/Cd and hydrogen fuel cells, as well as in electrochromic devices such as smart windows and flat panel displays. In accordance with the principles of the invention, anion- and cation-conducting membranes are formed. The gel composition of the membrane contains the ionic species within its solution phase such that the species behaves as in a liquid electrolyte, while at the same time, the solid gel composition prevents the solution phase from diffusing into the device. Methods of forming polymer based solid gel membranes of the present invention are also disclosed.

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: 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 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: 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: 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.

Abstract: Improved metal-air fuel cell battery systems having metal-fuel realized in the form of metal-fuel tape cartridges and metal-fuel cards, which can be either manually or automatically inserted within the power generation bay of the system. In order to produce a range of output voltages, the metal-fuel tape has a plurality of electrically-isolated metal-fuel tracks and the metal-fuel cards have a plurality of electrically-isolated metal-fuel strips. An output voltage configuration subsystem is provided for configuring the voltages produced by the individual cells to produce a desired output. A subsystem is provided for detecting oxide formation on the metal-fuel tracks and strips so that only metal-fuel that has been oxidized is reduced during recharging operations. A subsystem is also provided for controlling the flow of oxygen into the power generation head in order to control the power output from the system.

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: 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: 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. gelatinous) film layer integrated with the metal-fuel tape.

Abstract: A polymer-based electrolyte composition having excellent film-forming properties, flexibility, mechanical strength and high hydroxide conductivity is disclosed. The composition comprises an organic polymer having an alkyl quaternary ammonium salt structure; a nitrogen-containing, heterocyclic quaternary ammonium salt; and a metal hydroxide salt. In a preferred embodiment, the composition is cast in the form of a film that is suitable for use as an ion-conducting or other specialty membrane in a power source, such as for example an alkaline battery or fuel cell, that relies on hydroxide anion transport for its operation.