Gas management for metal-air batteries

Patent metadata

Field	Value
Publication number	US-2024113383-A1
Application number	US-202318352223-A
Country	US
Kind code	A1
Filing date	Jul 13, 2023
Priority date	Jul 13, 2022
Publication date	Apr 4, 2024
Grant date	—

Abstract

Systems, methods, and devices for gas management of metal-air batteries. Each one of a plurality of electrochemical cells may include at least one air electrode, a metal electrode, a vessel, and a liquid electrolyte between the at least one air electrode and the metal electrode in the vessel, with each one of the plurality of electrochemical cells defining a respective headspace above the liquid electrolyte in the vessel. A manifold may include ducting defining a shared vent and an outlet region, and the respective headspace of each one of the plurality of electrochemical cells may be fluidically coupled to the shared vent and in fluid communication with the outlet region of the ducting.

First claim

What is claimed is:

1 . A system for gas management of metal-air batteries, the system comprising:
a plurality of electrochemical cells, each one of the plurality of electrochemical cells including at least one air electrode, a metal electrode, a vessel, and a liquid electrolyte between the at least one air electrode and the metal electrode in the vessel, each one of the plurality of electrochemical cells defining a respective headspace above the liquid electrolyte in the vessel; and a manifold including ducting defining a shared vent and an outlet region, the respective headspace of each one of the plurality of electrochemical cells fluidically coupled to the shared vent and in fluid communication with the outlet region of the ducting.

2 . The system of claim 1 , further comprising a plurality of risers, wherein each one of the plurality of risers defines a respective cell vent, and the respective headspace of each one of the plurality of electrochemical cells is fluidically coupled to the shared vent via at least one cell vent of the plurality of risers.

3 . The system of claim 1 , further comprising at least one fan in fluid communication with the shared vent, wherein the at least one fan is operable to move gas along the shared vent and out of the ducting via the outlet region.

4 . The system of claim 3 , wherein the at least one fan is disposed in the shared vent.

5 . The system of claim 3 , wherein the at least one fan is oriented relative to the shared vent such that the at least one fan is operable to form negative pressure in the shared vent relative to ambient air pressure at the outlet region of the ducting.

6 . The system of claim 3 , wherein the ducting is dead ended along the shared vent, and the at least one fan pulls gas through the shared vent in a direction away from fluidic coupling of the plurality of electrochemical cells toward the outlet region.

7 . The system of claim 3 , wherein the ducting defines an inlet region, the respective headspace of each one of the plurality of electrochemical cells is in fluid communication with the shared vent along the ducting between the inlet region and the outlet region, and the at least one fan is operable to move air into the shared vent via the inlet region.

8 . The system of claim 3 , further comprising a controller and a first hydrogen sensor, wherein the controller is in electrical communication with the at least one fan and the first hydrogen sensor, the at first hydrogen sensor is arranged to sense hydrogen in the shared vent, and the controller is configured to receive a first signal from the first hydrogen sensor and to control speed of the at least one fan based on a first signal received from the first hydrogen sensor.

9 . The system of claim 8 , wherein the first hydrogen sensor is at least partially disposed in the shared vent between the outlet region of the ducting and the fluidic coupling of the respective headspace of each one of the plurality of electrochemical cells to the shared vent of the ducting.

10 . The system of claim 9 , further comprising a second hydrogen sensor in electrical communication with the controller, wherein the controller is further configured to receive a second signal from the second hydrogen sensor and to control speed of the at least one fan based on the first signal and the second signal.

11 . The system of claim 9 , further comprising an enclosure defining an intake opening, an exhaust opening, and a chamber, wherein the intake opening and the exhaust opening are in fluid communication with one another via an environment of the chamber, the plurality of electrochemical cells and the manifold are at least partially disposed in the environment of the chamber with the respective headspace of each one of the electrochemical cells and the shared vent of the ducting fluidically isolated from the environment of the enclosure, and the outlet region of the ducting is in fluid communication with an ambient environment outside of the enclosure.

12 . The system of claim 11 , further comprising a cooling fan in fluid communication with the environment of the chamber and activatable to pull air into the environment of the chamber via the intake opening and exhaust air from the environment of the chamber via the exhaust opening.

13 . The system of claim 12 , further comprising evaporative media supported along the intake opening of the enclosure, wherein evaporation of the evaporative media cools air pulled into the environment of the chamber through activation of the cooling fan.

14 . The system of claim 11 , further comprising a leak sensor arranged to sense hydrogen in the environment of the chamber, wherein the controller is in electrical communication with the leak sensor and the controller is further configured to receive a third signal from the leak sensor and to activate the cooling fan based on the third signal.

15 . The system of claim 1 , further comprising an event sensor including a housing, a film, and a wire, wherein the housing defines a first opening, a second opening, and a volume therebetween, the first opening is in fluid communication with the shared vent of the ducting, the film is disposed in the volume and fluidically isolates the first opening from the second opening in the volume, the wire is in electrical communication with a power source and the film to form at least a portion of a closed circuit and, at a predetermined pressure difference across the film, the film is burstable to switch the closed circuit to an open circuit.

16 . The system of claim 1 , wherein the plurality of electrochemical cells includes iron-air type battery cells, zinc-air type battery cells, lithium-air battery cells, or a combination thereof.

17 . A method of gas management of metal-air batteries, the method comprising:
receiving, from each of one or more hydrogen sensors, a respective signal indicative of hydrogen concentration in a shared vent defined by ducting and in fluid communication between each respective headspace of a plurality of electrochemical cells and an outlet region defined by the ducting; comparing the respective signal from each of the one or more hydrogen sensors to at least one predetermined threshold; and based on comparison of the respective signal of each of the one or more hydrogen sensors to the at least one predetermined threshold, controlling at least one fan in fluid communication with the shared vent and operable to move gas along the shared vent and out of the ducting via the outlet region.

18 . The method of claim 17 , wherein the at least one predetermined threshold corresponds to hydrogen concentration less than the lower flammability limit of hydrogen in air at a predetermined temperature and a predetermined pressure.

19 . The method of claim 17 , wherein the respective signal from at least one of the one or more hydrogen sensors is indicative of hydrogen concentration in the shared vent upstream of the at least one fan relative to a direction of gas flow through the at least one fan toward the outlet region of the ducting.

20 . The method of claim 17 , wherein receiving the respective signal from the one or more hydrogen sensors includes determining whether each of the one or more hydrogen sensors is operational, and controlling the at least one fan includes operating the at least one fan at 100 percent of rated operating speed if each of the one or more hydrogen sensors is determined to be non-operational.

Assignees

• Form Energy Inc

Inventors

• Ocampo Jaime Andres
• Friesen Grant
• Nansel Alli
• Banerjee Sid
• Smith Danielle Cassidy
• Parker Ellie
• Mckibben Nicholas
• Mohan Aruna

Classifications

• Y02E60/50

  Fuel cells · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M10/482

  for several batteries or cells simultaneously or sequentially · CPC title

• H01M10/4228

  Leak testing of cells or batteries · CPC title

• H01M50/209

  adapted for prismatic or rectangular cells (H01M50/216 takes precedence) · CPC title