CA1287335C - Battery powered light source - Google Patents
Battery powered light sourceInfo
- Publication number
- CA1287335C CA1287335C CA000548494A CA548494A CA1287335C CA 1287335 C CA1287335 C CA 1287335C CA 000548494 A CA000548494 A CA 000548494A CA 548494 A CA548494 A CA 548494A CA 1287335 C CA1287335 C CA 1287335C
- Authority
- CA
- Canada
- Prior art keywords
- cathode
- anode
- light source
- battery powered
- chamber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 229910052751 metal Inorganic materials 0.000 claims abstract description 34
- 239000002184 metal Substances 0.000 claims abstract description 34
- 239000012530 fluid Substances 0.000 claims abstract description 6
- 239000003792 electrolyte Substances 0.000 claims description 38
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical group [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 15
- 239000007795 chemical reaction product Substances 0.000 claims description 15
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 11
- 229910052782 aluminium Inorganic materials 0.000 claims description 11
- 239000011244 liquid electrolyte Substances 0.000 claims description 11
- 239000011780 sodium chloride Substances 0.000 claims description 10
- 238000006243 chemical reaction Methods 0.000 claims description 8
- 238000003487 electrochemical reaction Methods 0.000 claims description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 7
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 7
- 239000011777 magnesium Substances 0.000 claims description 7
- 229910052749 magnesium Inorganic materials 0.000 claims description 7
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 claims description 6
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 6
- 239000000654 additive Substances 0.000 claims description 5
- 230000000996 additive effect Effects 0.000 claims description 5
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 5
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 claims description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 230000005611 electricity Effects 0.000 claims description 3
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 claims description 2
- 239000000908 ammonium hydroxide Substances 0.000 claims description 2
- 239000001103 potassium chloride Substances 0.000 claims description 2
- 235000011164 potassium chloride Nutrition 0.000 claims description 2
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 claims 2
- 235000019270 ammonium chloride Nutrition 0.000 claims 1
- 229960002816 potassium chloride Drugs 0.000 claims 1
- 230000008093 supporting effect Effects 0.000 claims 1
- 235000010210 aluminium Nutrition 0.000 description 10
- 230000035508 accumulation Effects 0.000 description 3
- 238000009825 accumulation Methods 0.000 description 3
- 230000033228 biological regulation Effects 0.000 description 3
- 239000003518 caustics Substances 0.000 description 3
- 238000004140 cleaning Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 241001481828 Glyptocephalus cynoglossus Species 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000008020 evaporation Effects 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 230000002209 hydrophobic effect Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000002991 molded plastic Substances 0.000 description 2
- 230000007935 neutral effect Effects 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 239000013535 sea water Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 208000031501 Emergencies Diseases 0.000 description 1
- 208000036993 Frustration Diseases 0.000 description 1
- 241001465382 Physalis alkekengi Species 0.000 description 1
- 241001296096 Probles Species 0.000 description 1
- 208000003251 Pruritus Diseases 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 229940024545 aluminum hydroxide Drugs 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000000875 corresponding effect Effects 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 238000005286 illumination Methods 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 229920000136 polysorbate Polymers 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000036647 reaction Effects 0.000 description 1
- 235000002020 sage Nutrition 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M6/00—Primary cells; Manufacture thereof
- H01M6/02—Details
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M12/00—Hybrid cells; Manufacture thereof
- H01M12/04—Hybrid cells; Manufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type
- H01M12/06—Hybrid cells; Manufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
- H01M12/065—Hybrid cells; Manufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode with plate-like electrodes or stacks of plate-like electrodes
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21L—LIGHTING DEVICES OR SYSTEMS THEREOF, BEING PORTABLE OR SPECIALLY ADAPTED FOR TRANSPORTATION
- F21L2/00—Systems of electric lighting devices
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- General Engineering & Computer Science (AREA)
- Hybrid Cells (AREA)
- Eye Examination Apparatus (AREA)
- Endoscopes (AREA)
- Vessels And Coating Films For Discharge Lamps (AREA)
- Luminescent Compositions (AREA)
Abstract
BATTERY POWERED LIGHT SOURCE
Abstract of the Invention A battery powered light source comprising an electric light bulb; a plurality of air cathodes; a plurality of metal anodes, one for each cathode; a plurality of electrically nonconductive housings disposed adjacent to each other, wherein each housing encloses a respective chamber containing one cathode and one anode which are spaced from each other and form an anode-cathode pair and also encloses a cavity which is below the anode-cathode pair and is in fluid flow communication with the chamber, each housing having a portion defining at least one air passage from its chamber to an adjacent housing, and an open-ing through which a surface of the contained cathode is exposed to air in the passage. The housings are secured to each other in such arrangement that their respective air-passage-defining portions cooperative-ly define at least one common air passage. Circuit elements are provided for electrically connecting the anode-cathode pairs to each other and to the electric light bulb.
Abstract of the Invention A battery powered light source comprising an electric light bulb; a plurality of air cathodes; a plurality of metal anodes, one for each cathode; a plurality of electrically nonconductive housings disposed adjacent to each other, wherein each housing encloses a respective chamber containing one cathode and one anode which are spaced from each other and form an anode-cathode pair and also encloses a cavity which is below the anode-cathode pair and is in fluid flow communication with the chamber, each housing having a portion defining at least one air passage from its chamber to an adjacent housing, and an open-ing through which a surface of the contained cathode is exposed to air in the passage. The housings are secured to each other in such arrangement that their respective air-passage-defining portions cooperative-ly define at least one common air passage. Circuit elements are provided for electrically connecting the anode-cathode pairs to each other and to the electric light bulb.
Description
~L~B7335 ~ATTE~Y P0WERED LIGRT SOURCE
Backqround of ~he Invention The invention relates to a battery powered light source and to applications thereof. Our inven-tion is useful as an inexpensive and convenient means for providing light for an extended period of time.
It is useful, for example, on barges in the shipping industry. Battery powered light sources of the pre-sent invention can power â light bulb that emits light in accordance with the United States Coast Guard regulations for a period of about 28 days.
Metal/air batteries produce electricity by the electrochemical coupling of a reactive metal^lic anode to an air cathode through a suitable electro-lyte in a cell. As is well known in the art, an air cathode is a typically sheetlike member, having oppo-site surfaces respectively exposed to the atmosphere and to the aqueous electrolyte of the cell, in which (during cell operation) at~ospheric oxygen discoci-ates while metal of the anode oxidi2es, providing a usable electric current flow through externa~ cir-cuitry connected between the anode and cathode. The air cathode must be permeable to air but substanti-ally hydrophobic ~so that aqueous electrolyte will not ~eep or leak through it), and must incorporate an electrically conductive element to which the external circuitry can be connected; for instance, in present-day commercial practice, the air cathode is commonly constituted of active carbon (with or without an 3~ added dissociation-promoting catalyst) containing a finely divided hydrophobic polymeric material and incorporating a metal screen as the conductive ele-~L~8733~
-- 2 ~
ment. A variety of ~node metals have been used or proposed; among them, alloys of aluminum and alloy~
of magnesium are considered especially advantageous for particular applications, owing to their low cost, light weight, and ability to function as anodes in metal/air batteries using neutral electrolytes ~uch as sea water or other aqueous saline solutions.
Thus, by way of more specific example, an illustrative aluminum/air cell co~prises a body of aqueous saline electrolyte, a sheetlike air cathode having one surface exposed to the electrolyte and the other surface exposed to air, and an aluminum alloy anode member (e.g. a flat plate) im~ersed in the electrolyte in facing spaced relation to the first~
mentioned cathode surface. The discharge reaction for this cell may be written 4Al + 32 ~ 6~20 - 4Al(0~)3.
As the reaction proceedc, copious production of the alu~inum h-ydroxide reaction product (initially having a gel-like consistency) in the sp~ce ~etween anode and cathode ultimately interferes with cell opera-tion, necessitating periodic cleaning and electrolyte replacement. The cell may be recharged mechanically by replacing the aluminu~, anode when substantial anode metal has been consumed in the cell reaction.
Metal/air batteries have an essentially infi-nite shelf-storage life so long as they are not acti-vated with electrolyte, making them very suitable for standby or emergency uses. For example, an emergency lamp or lantern can be constructed with a metal/air battery such as an aluminum/air battery, and a sepa-rate container of electrolyte can be stored with the battery, or be readily available within its intended ', 3733~i environment of use. When a need for use of an emer-gency light arises~ a user c~n merely activate the metal-air ~ttery (by r~imply adding electrolyte) and be provided with useful light. _ _ S As any consumer can appreciate, a lantern with an infinite storage life is much more reliable than common dry-cell battery-powered lanterns that have batteries which tend to deteriorate with shelf storage. Reaching for a dry-cell-powered lantern in an emergen~, only to find that the batteries have detexiorated to a discharged condition, is a frustra-tion experienoed by many people. A metal/air-batter-y-p~ ered lantern avoids such a proble~, ~ecause the cells cannot be depleted until the battery is filled with electrolyte.
The voltage of a single metal/air cell such as a magnesium or aluminum air cell i~ or may be less than that r~ uired for a lantern or other use. In such case, as well as for other purposes, a pl ~ ~ ity (typically t~o) of the cells may be connected in seriefi. ~ sirable characteristics of a plural-cell metal/air battery include structural simplicity ano compactness, ease of activation (bringing the elec-trodes into contact with electrolyte) by an unskilled user, and avoidance of current ~ ths through the electrolyte bet~een electrodec of like polarity in different cells.
The pr ~ision of a metal/air battery-powered lantern for emergency situations is proposed in hata-kabe, ~Magnesium-Air Sea h~ater Primary Batteries,~
Solar Çgll~, Vol. II (Cleveland: JEC Press Inc., 1979). This publication shows a ~life-torch~ with a series-connected twin cell battery of ~inside-out~
construction, namely a pair of spaced-a~rt ~agnesium anodes having a pair of cathodes interposed bet~een .
, .
733~i them and mutually defining a common alr space. Each anode-cathode pair is surrounded by a ~eparate elec-trolyte spa oe (within a housing) to prevent or mini-mize electrolytic shunting between the battery cells.
s As those skilled in the art can appreciate, ~in oe the anodes of a pair of series-connected metal-air bat-tery cells are at different potentials, the existence of a c~rrent path through the electrolyte between the anodes of the respective cells will cause undesired shunting of current and can signific~ntly impair oell efficiency.
The above-cited publication contemplates use of the describec device at sea, attached to a life jacket so that the b2ttery floats substantially im-mersed in sea water, which enters inlets formed in the housing, one for each cell, separately filling each of the two electrolyte spaces. These inlets are ~idely spaced apart to redu oe electrolytic shunting through the ambient sea. Such a battery uses the sea as the saline electrolyte for the battery and iso-lates this eIectrolyte into two separate tanks, ore for each batter~ cell. Thus, to activate the des-cribed battery, one need only insert the lantern into the sea.
On land, utilization of a batterS constructed in accordance ~ith the above-cited publication would re~uire pouring saline electrolyte into each of the battery inlets. As one can appreciate, the pouring of electrolyte into separate inlet ports can be ex-tremely difficult, especially in the dark. An easier method of filling electrolyte into the batteries is desirable for land applic~tions. Moreover, the de-vice of the above-cited publication is evidently designed for a single use in a marine emergency; for 3s a routine consumer land application, such as during ~:61733~i power failure emergencies or extremely inclement weather, it would be desirable to have a battery that could be repeatedly activated by pouring electrolyte into the cells, and repeatedly deactivated by removing the electrolyte from the cells and cleaning out reaction products formed within the cells, without the hindrance of separate tanks for the two cells.
Also, it would be desirable to retard the accumulation of reaction product in the anode-cathode gap of a metal/air cell or battery, such as an aluminum~air battery, thereby to prolong the period of active use of the cell or battery between cleanings. In this regard, it has heretofore been proposed to provide a relatively wide anode-cathode gap for promoting flow of fresh electrolyte around the gap edges, generally parallel to the electrode surfaces; but cell efficiency decreases with increasing anode-cathode distances. Another proposal, set forth in the Handbook of Batteries and Fuel Cells (McGraw-Hill, 1984), p. 30`11, is to prevent hydroxide gel formation by employing a caustic electrolyte rather than a neutral saline electrolyte, but caustic electrolytes are disadvantageous (as compared to saline electrolyte) from the standpoint of convenience, cost, and safety in handling.
Hamlen et al., United States Patent No.
4,626,482, discloses a metal/air battery having plural series-connected cells, including a tank for holding a body of liquid electrolyte, and an electrically nonconductive frame carrying a plurality of air cathodes facing a common air chamber and a like plurality of metal anodes respectively juxtaposed to the cathodeæ outside the air chamber, the ~rame being removably insertable in the tank and engaging the tank ~;287335 wall, ~hen inserted, ~o as to divide the tank into a plurality of separate and substantially electrically isolated electrolyte-holding ~ones each containing one anode-cathode p~ir.
The present invention, in an important speci-fic sense, provides a battery-powered light source that is particularly useful on barges in the shipping industry. In order to conform to ~nited States Coast Guard regulations, for marking barges at night, bar-ges must have light sour oe s that emit light of at least 0.9 candela to a distan oe of one mile. It is current industry practice to power lights with dry cell batteries which after a fe~ nights are inc~pRble of powering a light bulb. Depleted dry cell batte-ries are discarded each night or ever} other night and replaced with new dry cell ~atteries. Dry cell batteries are also inconvenient in that they often contain mercury which produ oe s a toxic reaction pro-duct and have a short shelf-life as compared to the ~ ttery of the present invention. Batteries of the present invention are desirable because they overcome the deficiencies of dry cell ~ tterieC currently used on barges in the shipping ind~stry.
Summary of the Invention 2s In a broad sense, the present invention con templates the provision of a b~ttery powered light source comprising a plurality of air cathodes; a plurality of metal anodes, one for each cathode; a plurality of electrically nonconductive housings disposed adjacent to each other, wherein each housing encloses a respective chamber containing one cathode and one anode which are spaced from each other and form an anode-cathode pair and also encloses a cavity which is below the anode-cathode pair and is in fluid ~Z~13~5 flow c~mmunication with the chamber, and each housing has means defining at least one air passage fro~ its chamber to the chamber of an adja oe nt housing; means to attach the housings to each other and to thereby connect the air passaqes into at least one common air passage, the housings having openings through which surfâces of their respectively contained cathodes are e~posed to air in said passage; and circuit means for electrically connecting the anode-cathode pairs to each other.
In one embodiment of the present invention, the battery powered light source additionally compri-ses an electric light bulb which is electrically connected by circuit means to the anode-cathode pairs. In another embodi~,ent of the present inven-tion, the plurality of air cathodes is two, the plur-ality of metal anodes ic two, the plurality of elec-trically nonconductive housings disposed adja oent to each other is two, and the battery powered light source additionally comprises an electric light bulb which is electrically connected b~ circuit means to the anod~-cathode pairs.
Further features and advantages of the invention will be apparent from the detailed description here-inbelow set forth, together with the accompan~ring drawings.
~ief Descri~ti ~ _Qf_the Drawinq~
Fig. 1 is a perspective view of a barge light device embodying the present invention in a particu-lar form;
Fig. 2 is an exploded perspective view, partly broken away, of one cell of the device of Fig. l;
Fig. 3 is an enlarged sectional elevational view taken along the line 3-3 of Fig. l;
~8733~i Fig. 4 is ~ similarly enlarged elevational vieu of the interior of one cell, taken along the line 4-4 of Fig. l; and Fig. 5 is a further enlarged detail sectional view of the region enclosed by broken line circle S
in ~ig. 3.
Detailed Description of the InYention The present invention is a battery powered light source comprising a plurality of air cathodes formed using a plurality of pvrous carbon plates; a plur~ ity of metal anodes, one for each cathode, wherein said metal anodes are aluminum, magnesium or a metal alloy containing suitable amounts of alumi-num, magnesium or mixtures thereof; a plurality of electrically nonconductive housings disposed adja oent to each other, wherein each housing encloses a res-pective chamber containing one cathode and one an:ode which are spaced fro~, each other and form an anode-cathode pair and also encloses a cavity which is belo~ th~ anode-cathode ~ ir and is in fluid fl ~
cc~,mur,icction ~ith the chamber, and e2ch housing has means defining at least one air ~ ssage from its chamber to the chamber of ~n adjaoent housing; means to attach the housings to each other and to thereby connect the air passages into at least one common air passage; and circuit means for electrically connec-ting the anode-cathode pairs to each other.
In one embodiment of the present invention, the battery powered light source additionally compri-ses an electric light bulb which is electrically connected by circuit means to the anode-cathode pairs. In another embodiment of the present inven-tion, the plur~ ity of air cathodes is two, the plur-ality of metal anodes i5 two, the plurality of elec-';' ': .
~l~ 51733S
g trically nonconductive housings disposed adja oent to each other i6 two, and the battery powered light source additionally comprises an electric light bulb which is electrically connected by circuit means to the anode-c~thode pairs.
The bulb may be any one of a variety of light b~ bs which is capable of emitting light. For exam-ple, the bulb ~lay be a fluoresoent, strobe, incandes-oent, or co~lmon flash light bulb In a preferred embodiment of the present invention, the bulb is capable of emitting li~ht of at least 0.9 candela to a distan oe of one mile, which is the intensity of lioht re~uired by United States Coast Guard regula-tions to be emitted for ~,arking barges at night. A
preferred embodiment of the present invention contem-plates a cover surrounding the bulb to direct light from the light source in a generally horizontal direction. The cover functions in a manner such that light emitted from a bulb that emits a total inten-sity of light less than 0.9 candela i~ directed in a generally horizontal direction cO that the bulb, ~her vie~ed fro~ that direction appearC to be emitting an intensity of light of at least 0.9 candela.
In a preferred embodiment of the present invention, the metal anode is aluminum. ~ uminu~, is conveniently light-weight and inexpensive. It has an indefinite shelf-life and efficiently reacts with oxygen to produ oe electricity. The metal may also be magnesium, or an alloy containing suitable amounts of alu~inum, magnesium or mixtures thereof. Zinc is not a suitable ~etal for the present invention bec3use dangerous caustic electrolyte is necessary to promote an efficient electrochemical reaction. The anode preferably has vertical slots which are effective in 3s pro~oting egress of reaction product from, and suffi-.
~L28~335 cient electrolyte flow into and through, the gap or space between the anode and cathode to retard accumu-lation of reaction products therein. The anode may be separated from the cathode by a distan oe of about one-sixteenth inch to about two inches apart. A
preferred distance is about one-sixteenth inch to about three-eighths inch, more preferably about one-eighth inch to about three-eighths inch, and a most preferred distance is about one-eighth inch to about one-quarter inch, for advantageous efficiency without undue shortening of useful operatin~ time because of accumulation of electrochemical reaction product. In a preferred embodiment, the anode plate is shaped so that scrap is minimized when the anode plate is cut.
In a preferre~ embodiment, the anode weighs about one-half pound. The anode plate is essentially a rectangular shape with a narro~ arm extended from one long side of the rectangle, and an indentation, simi-lar in shape to the narrow arm, opposing the narrow arm and indenting the anode plate fro~ the opposite lonc side.
The cavity positioned bel ~ the anode-cathode pair has sufficient capacity to contain electrochemi-cal reaction product generated during battery use.
2s By rem~ ing the reaction product from the area sur-rounding the anode-cathode pair, internal resistan oe is minimized and the electroche~;ical reaction pro-ceeds efficiently. The presence of the cavity allows batteries of the present invention to have extended reaction activity.
The battery powered light source is activated by filling each chamber to a ~,uitable level with a saline solution or other aqueous electrolyte. Liquid electrolyte useful in the present invention may be any one of those electrolytes commonly used in batte-~733S
ries. The liquid electrolyte is water containing ~n additive to enhance electrical conductivity. The addi-tive may be sodium chloride r potassium chloride, ammoni-um chloride, sodium hydroxide, potassium hydroxide or s ammonium hydroxide. Sodium chloride is preferred be-cause it is relatively convenient and inexpensive.
Each hou6ing of the present invention ha~ a vertical wall having an interior side facing the cham-ber. The source includes means to support each anode in its respective chamber comprising one or more platforms which project from the interior side of the vertical wall of the housing and form flat horizontal surfaces on which the anode rests. An activated carbon plate is glued to the interior side of the vertic21 ~all to form the cathode. Each housing co~prises two electrically nonconductive shells having vertical edges joined to form a vertical seam. Joining shells to form a vertical seam is an efficient, cost-effective manner of construc-ting the housing. Use of expensive large-cavity molds is not necessary when the housing is constructed by joir,ing edges of two shells formea fron, shallow molds.
In a preferred erbodiment of the present inven-tion, the ~ttery powered light source has means to control air fl ~ into the common air p~ssage or passa-ges. Control of air flow is important in minimizing water evaporation which might reduoe the extent of the electrochemical reaction and hence the life of the battery In another embodiment of the present invention, the battery powered 1ight source has means to alternate-ly halt and recommen oe the electrochemical reaction.
Thus, the life of a battery of the present invention having anode, cathode, and electrolyte to provide power sufficient to emit light of an intensity of 0.9 candela to a distance of one mile from a light bulb continuously 3~287335 or about 28 days may be extended if said ~ttery pow-ered light ~o~ ce has mean~ to alternately halt and recommence the electrochemical reaction. Ihe ~ean~ may be a ~witch such as a manual ~witch or a ~olar switch.
Referring to the drawings, the invention is ill~s-trated as embodied in a barge light device 10 comprising two essentially identical metal/air cell~ lla and llb and a cap member 12 shaped to provide a seat 14 for mounting an electrically ener~izable light sour oe (not shown), e.g. an incandescent or other lamp, in a posi-tion such that the lamp projects above the cap member.
The two cells and the cap are suitably glued or other-wise bonded togethe! to constitute an effectively unita-ry structure.
ach cell has a housing constit~ted of two facing, pan-shaped, molded plastic elements 16 and 18 glued or other~ise bonded together at their facing rims in a continuous sealed joint or seam 20 so as cooperatively to define a generally rectangular chamber 22 for holding a liquid electrolyte. The elements 16 and 18 respec-tively have ~iajor verti~l walls 24 and 26, each extend-ing from top to botto~ and from end to end of the cell, disposed in qenerally parallel, spaced relation to each other, thereby to serve respectively as the outer and inner walls of the cell. Wall 26 is formed with an upper portion 26a having a large rectangular opening 28 across which extend a plurality of mullions 30; this portion 26a is rec~ssed, from end to end of the cell, with respect to the wall portions 26b and 26c respec-tively above and below it. In the assembled device 10, the walls 26 of the two cells lla and llb are adhered together in facing contiguous relation to each other with their respective recessed portions 26a in register, forming a common laterally confined air passage 32 extending horizonally bet~een, and open at each end of, the cells.
Ihe wall portion 26c of each cell may be formed with a horizontally spaced pair of respectively convex and concave dimples 26d for mating with the correspon-ding dimples of the other oell to facilitate assembly of the device. At the top of each cell housing element 16 there is provided a port 16a, closed by a plug 16b, for introduction of liquid electrolyte to the chamber 22;
the plug may have a perforation or other vent opening (not shown) for release of gas generated by electroly-tic reaction within the cell.
Within the element 18 of each cell lla or llb, an air cathode 34 and a suitable metal (e.g. aluminum or alu~,inum alloy) anode 36 are disposed in facing, para-llel, more or less closely spaced relation to each other lS (so as to define an anode-cathode gap G between themJ
with their facing surfaces exposed for contact with liquid electrolyte (not shown) in the chamber 22 of the cell. The air cathode is conveniently a generally rectangular sheet member fabricated of activated car-bon, incorporating an electrically conductive material such as ~ire mesh; it is dimensioned and positionea to extend entirely over the opening 28 ~ith its edges sealingly adhered to the interior surface of wall 26 all around the periphery of the latter opening so as to com-plete the liquid-tight enclosure of chamber 22, being supported externally by the mullions 30. Thus, while one major surface of the air cathode is exposed to liquid electrolyte within the cell, the other major surface of the air cathode is exposed (through the opening 28) to air in the air passage 32. The ~,etal anode is a flat, generally rectangular metal plate of substantial thickness having a plurality of elongated vertical slots 36a opening through its major surfa oe s, and is supported at its lower edge on (and adhered to) a horizontally spaced pair of luglike projections ~8 molded in the wall 26.
~7335 At its top edge, the air Gathode 3~ ha~ ~ vertical-ly extending tab 34a projecting upwardly through a slot 40 in the top of the houfiing element 18. Similarly, the metal ~node 36 has a tab 36b projecting upwardly through a slot 42 in the top of the same housing element. In the assembled cell, a suitable sealing material is applied to close the slots around the tabs, and lead wires (not shown) are respectively secured to the ex posed tab extremities above the housing element. ~or convenience and economy of manufacture, the metal anodes may be cut or punched in sucoe ssion from an extended body of aluminum plate, with the tab 36b of each anode cut out of the body of the anode ahe2d of it, leaving a vertical notch 36c in the lower portion of the anode body.
The dimension and dicposition of the opening 28, air cathode 34, metal anode 36 and luglike projections 38 in each oell are chosen such that the lo~er edges of the cathode and anode are spaced substantially above the floor of the chamber 22. Consequently, each chamber 22 includes a cavity or reservoir portion 22a of subctan-tial volume entirely below the cell el~ctrodes, exten-ding directly beneath the anode-cathode gap of the cell as well as outwardly thereof. This reservoir portion, at least equal in horizontal cross-sectional area to the upper (electrode-containing) portion of the chamber, has a vertical extent (bel ~ the electrodes) that may be as much as one-third, or even more, of the entire vertical extent of the chamber.
The cap member 12 is a unitary, integral, molded plastic body, disposed above and extending entirely over the tops of the two cell housing ele~ents 18 in the assembled device 10, thereby to enclose the tabs 34a, 36b and associated lead wires of both cells. Lateral flange portions 12a of the cap member respectively extend outwardly of, and in contiguous parallel relation to, the top portions of the ~eams 20 of the two oells, and are adhered thereto, while end flange portions 12b of the cap member ~ubstantially complete the enclosure S of the electrode tabs and lead wires.
Before the cap member is bonded to the cells lla and llb, the lead wires are connected between the cells and to terminals tnot shown, but disposed within, i.e.
under, the cap member) of a light source mounted in the cap member seat 14, so as to connect the cells and light source in a series circuit. These electrical connections are isolated from the cell interiors by the abovedescribed sealing of the slots 40 and 42 and are protected by the cap member when the latter is adhered to and over the cells 112 and llb. The light source is supported by and projects above the cap mount 14 to provide ~esired illumination.
In use, the device 10 may be activated by filling the chambers 22 of the two cells with salt water (e.g.
sea ~ater) or other appropriate electrolyte through the ports 16a, which are then closea; alternatively, if the device is provided with a ~ itch (not sh ~ n) in the aforementioned circuit, it may be prefilled with elec-trolyte and turned on by operation of the switch.
Ascuming proper selection and configuration of the light so~ ce, and appropriate dimensioning of the cells and their electrodes lall matters readily ~ithin the ordina-ry skill of the art, given the foregoing description), a barge light designed to ~eet Coast Guard standards and having an advantageously long service lifetime is there-by provided. Reaction product such as aluminum hydr-oxide, formed in the anode-cathode gaps of the cells, passes downwardly from that gap and from the anode slots into the cavity or reservoir portion 22a of each cell chamber; the capacity of these cavities is ~uch as to '.
~l~87;33S
enable extended operation before the accumulatin~ reac-tion product significantly interferes ~ith cell opera-tion. Air flows through the common lateral pa~sage 32 defined ~tween the cells, to permeate the air cathodes as required for the cells to operate, but because this passage is laterally confined bet~een the two cells, the flow of air is limited or controlled, as desired to minimize evaporation losses of the liquid electrolyte in the cells. The device is ~imple and inexpensive yet sturdy and reliable in construction, and is easy to manufacture, assemble and use.
It is to be understood that the invention is not limited to the features and embodiments hereinabove specifically set forth but may be ~rried out in other ways without departure from its spirit.
Backqround of ~he Invention The invention relates to a battery powered light source and to applications thereof. Our inven-tion is useful as an inexpensive and convenient means for providing light for an extended period of time.
It is useful, for example, on barges in the shipping industry. Battery powered light sources of the pre-sent invention can power â light bulb that emits light in accordance with the United States Coast Guard regulations for a period of about 28 days.
Metal/air batteries produce electricity by the electrochemical coupling of a reactive metal^lic anode to an air cathode through a suitable electro-lyte in a cell. As is well known in the art, an air cathode is a typically sheetlike member, having oppo-site surfaces respectively exposed to the atmosphere and to the aqueous electrolyte of the cell, in which (during cell operation) at~ospheric oxygen discoci-ates while metal of the anode oxidi2es, providing a usable electric current flow through externa~ cir-cuitry connected between the anode and cathode. The air cathode must be permeable to air but substanti-ally hydrophobic ~so that aqueous electrolyte will not ~eep or leak through it), and must incorporate an electrically conductive element to which the external circuitry can be connected; for instance, in present-day commercial practice, the air cathode is commonly constituted of active carbon (with or without an 3~ added dissociation-promoting catalyst) containing a finely divided hydrophobic polymeric material and incorporating a metal screen as the conductive ele-~L~8733~
-- 2 ~
ment. A variety of ~node metals have been used or proposed; among them, alloys of aluminum and alloy~
of magnesium are considered especially advantageous for particular applications, owing to their low cost, light weight, and ability to function as anodes in metal/air batteries using neutral electrolytes ~uch as sea water or other aqueous saline solutions.
Thus, by way of more specific example, an illustrative aluminum/air cell co~prises a body of aqueous saline electrolyte, a sheetlike air cathode having one surface exposed to the electrolyte and the other surface exposed to air, and an aluminum alloy anode member (e.g. a flat plate) im~ersed in the electrolyte in facing spaced relation to the first~
mentioned cathode surface. The discharge reaction for this cell may be written 4Al + 32 ~ 6~20 - 4Al(0~)3.
As the reaction proceedc, copious production of the alu~inum h-ydroxide reaction product (initially having a gel-like consistency) in the sp~ce ~etween anode and cathode ultimately interferes with cell opera-tion, necessitating periodic cleaning and electrolyte replacement. The cell may be recharged mechanically by replacing the aluminu~, anode when substantial anode metal has been consumed in the cell reaction.
Metal/air batteries have an essentially infi-nite shelf-storage life so long as they are not acti-vated with electrolyte, making them very suitable for standby or emergency uses. For example, an emergency lamp or lantern can be constructed with a metal/air battery such as an aluminum/air battery, and a sepa-rate container of electrolyte can be stored with the battery, or be readily available within its intended ', 3733~i environment of use. When a need for use of an emer-gency light arises~ a user c~n merely activate the metal-air ~ttery (by r~imply adding electrolyte) and be provided with useful light. _ _ S As any consumer can appreciate, a lantern with an infinite storage life is much more reliable than common dry-cell battery-powered lanterns that have batteries which tend to deteriorate with shelf storage. Reaching for a dry-cell-powered lantern in an emergen~, only to find that the batteries have detexiorated to a discharged condition, is a frustra-tion experienoed by many people. A metal/air-batter-y-p~ ered lantern avoids such a proble~, ~ecause the cells cannot be depleted until the battery is filled with electrolyte.
The voltage of a single metal/air cell such as a magnesium or aluminum air cell i~ or may be less than that r~ uired for a lantern or other use. In such case, as well as for other purposes, a pl ~ ~ ity (typically t~o) of the cells may be connected in seriefi. ~ sirable characteristics of a plural-cell metal/air battery include structural simplicity ano compactness, ease of activation (bringing the elec-trodes into contact with electrolyte) by an unskilled user, and avoidance of current ~ ths through the electrolyte bet~een electrodec of like polarity in different cells.
The pr ~ision of a metal/air battery-powered lantern for emergency situations is proposed in hata-kabe, ~Magnesium-Air Sea h~ater Primary Batteries,~
Solar Çgll~, Vol. II (Cleveland: JEC Press Inc., 1979). This publication shows a ~life-torch~ with a series-connected twin cell battery of ~inside-out~
construction, namely a pair of spaced-a~rt ~agnesium anodes having a pair of cathodes interposed bet~een .
, .
733~i them and mutually defining a common alr space. Each anode-cathode pair is surrounded by a ~eparate elec-trolyte spa oe (within a housing) to prevent or mini-mize electrolytic shunting between the battery cells.
s As those skilled in the art can appreciate, ~in oe the anodes of a pair of series-connected metal-air bat-tery cells are at different potentials, the existence of a c~rrent path through the electrolyte between the anodes of the respective cells will cause undesired shunting of current and can signific~ntly impair oell efficiency.
The above-cited publication contemplates use of the describec device at sea, attached to a life jacket so that the b2ttery floats substantially im-mersed in sea water, which enters inlets formed in the housing, one for each cell, separately filling each of the two electrolyte spaces. These inlets are ~idely spaced apart to redu oe electrolytic shunting through the ambient sea. Such a battery uses the sea as the saline electrolyte for the battery and iso-lates this eIectrolyte into two separate tanks, ore for each batter~ cell. Thus, to activate the des-cribed battery, one need only insert the lantern into the sea.
On land, utilization of a batterS constructed in accordance ~ith the above-cited publication would re~uire pouring saline electrolyte into each of the battery inlets. As one can appreciate, the pouring of electrolyte into separate inlet ports can be ex-tremely difficult, especially in the dark. An easier method of filling electrolyte into the batteries is desirable for land applic~tions. Moreover, the de-vice of the above-cited publication is evidently designed for a single use in a marine emergency; for 3s a routine consumer land application, such as during ~:61733~i power failure emergencies or extremely inclement weather, it would be desirable to have a battery that could be repeatedly activated by pouring electrolyte into the cells, and repeatedly deactivated by removing the electrolyte from the cells and cleaning out reaction products formed within the cells, without the hindrance of separate tanks for the two cells.
Also, it would be desirable to retard the accumulation of reaction product in the anode-cathode gap of a metal/air cell or battery, such as an aluminum~air battery, thereby to prolong the period of active use of the cell or battery between cleanings. In this regard, it has heretofore been proposed to provide a relatively wide anode-cathode gap for promoting flow of fresh electrolyte around the gap edges, generally parallel to the electrode surfaces; but cell efficiency decreases with increasing anode-cathode distances. Another proposal, set forth in the Handbook of Batteries and Fuel Cells (McGraw-Hill, 1984), p. 30`11, is to prevent hydroxide gel formation by employing a caustic electrolyte rather than a neutral saline electrolyte, but caustic electrolytes are disadvantageous (as compared to saline electrolyte) from the standpoint of convenience, cost, and safety in handling.
Hamlen et al., United States Patent No.
4,626,482, discloses a metal/air battery having plural series-connected cells, including a tank for holding a body of liquid electrolyte, and an electrically nonconductive frame carrying a plurality of air cathodes facing a common air chamber and a like plurality of metal anodes respectively juxtaposed to the cathodeæ outside the air chamber, the ~rame being removably insertable in the tank and engaging the tank ~;287335 wall, ~hen inserted, ~o as to divide the tank into a plurality of separate and substantially electrically isolated electrolyte-holding ~ones each containing one anode-cathode p~ir.
The present invention, in an important speci-fic sense, provides a battery-powered light source that is particularly useful on barges in the shipping industry. In order to conform to ~nited States Coast Guard regulations, for marking barges at night, bar-ges must have light sour oe s that emit light of at least 0.9 candela to a distan oe of one mile. It is current industry practice to power lights with dry cell batteries which after a fe~ nights are inc~pRble of powering a light bulb. Depleted dry cell batte-ries are discarded each night or ever} other night and replaced with new dry cell ~atteries. Dry cell batteries are also inconvenient in that they often contain mercury which produ oe s a toxic reaction pro-duct and have a short shelf-life as compared to the ~ ttery of the present invention. Batteries of the present invention are desirable because they overcome the deficiencies of dry cell ~ tterieC currently used on barges in the shipping ind~stry.
Summary of the Invention 2s In a broad sense, the present invention con templates the provision of a b~ttery powered light source comprising a plurality of air cathodes; a plurality of metal anodes, one for each cathode; a plurality of electrically nonconductive housings disposed adjacent to each other, wherein each housing encloses a respective chamber containing one cathode and one anode which are spaced from each other and form an anode-cathode pair and also encloses a cavity which is below the anode-cathode pair and is in fluid ~Z~13~5 flow c~mmunication with the chamber, and each housing has means defining at least one air passage fro~ its chamber to the chamber of an adja oe nt housing; means to attach the housings to each other and to thereby connect the air passaqes into at least one common air passage, the housings having openings through which surfâces of their respectively contained cathodes are e~posed to air in said passage; and circuit means for electrically connecting the anode-cathode pairs to each other.
In one embodiment of the present invention, the battery powered light source additionally compri-ses an electric light bulb which is electrically connected by circuit means to the anode-cathode pairs. In another embodi~,ent of the present inven-tion, the plurality of air cathodes is two, the plur-ality of metal anodes ic two, the plurality of elec-trically nonconductive housings disposed adja oent to each other is two, and the battery powered light source additionally comprises an electric light bulb which is electrically connected b~ circuit means to the anod~-cathode pairs.
Further features and advantages of the invention will be apparent from the detailed description here-inbelow set forth, together with the accompan~ring drawings.
~ief Descri~ti ~ _Qf_the Drawinq~
Fig. 1 is a perspective view of a barge light device embodying the present invention in a particu-lar form;
Fig. 2 is an exploded perspective view, partly broken away, of one cell of the device of Fig. l;
Fig. 3 is an enlarged sectional elevational view taken along the line 3-3 of Fig. l;
~8733~i Fig. 4 is ~ similarly enlarged elevational vieu of the interior of one cell, taken along the line 4-4 of Fig. l; and Fig. 5 is a further enlarged detail sectional view of the region enclosed by broken line circle S
in ~ig. 3.
Detailed Description of the InYention The present invention is a battery powered light source comprising a plurality of air cathodes formed using a plurality of pvrous carbon plates; a plur~ ity of metal anodes, one for each cathode, wherein said metal anodes are aluminum, magnesium or a metal alloy containing suitable amounts of alumi-num, magnesium or mixtures thereof; a plurality of electrically nonconductive housings disposed adja oent to each other, wherein each housing encloses a res-pective chamber containing one cathode and one an:ode which are spaced fro~, each other and form an anode-cathode pair and also encloses a cavity which is belo~ th~ anode-cathode ~ ir and is in fluid fl ~
cc~,mur,icction ~ith the chamber, and e2ch housing has means defining at least one air ~ ssage from its chamber to the chamber of ~n adjaoent housing; means to attach the housings to each other and to thereby connect the air passages into at least one common air passage; and circuit means for electrically connec-ting the anode-cathode pairs to each other.
In one embodiment of the present invention, the battery powered light source additionally compri-ses an electric light bulb which is electrically connected by circuit means to the anode-cathode pairs. In another embodiment of the present inven-tion, the plur~ ity of air cathodes is two, the plur-ality of metal anodes i5 two, the plurality of elec-';' ': .
~l~ 51733S
g trically nonconductive housings disposed adja oent to each other i6 two, and the battery powered light source additionally comprises an electric light bulb which is electrically connected by circuit means to the anode-c~thode pairs.
The bulb may be any one of a variety of light b~ bs which is capable of emitting light. For exam-ple, the bulb ~lay be a fluoresoent, strobe, incandes-oent, or co~lmon flash light bulb In a preferred embodiment of the present invention, the bulb is capable of emitting li~ht of at least 0.9 candela to a distan oe of one mile, which is the intensity of lioht re~uired by United States Coast Guard regula-tions to be emitted for ~,arking barges at night. A
preferred embodiment of the present invention contem-plates a cover surrounding the bulb to direct light from the light source in a generally horizontal direction. The cover functions in a manner such that light emitted from a bulb that emits a total inten-sity of light less than 0.9 candela i~ directed in a generally horizontal direction cO that the bulb, ~her vie~ed fro~ that direction appearC to be emitting an intensity of light of at least 0.9 candela.
In a preferred embodiment of the present invention, the metal anode is aluminum. ~ uminu~, is conveniently light-weight and inexpensive. It has an indefinite shelf-life and efficiently reacts with oxygen to produ oe electricity. The metal may also be magnesium, or an alloy containing suitable amounts of alu~inum, magnesium or mixtures thereof. Zinc is not a suitable ~etal for the present invention bec3use dangerous caustic electrolyte is necessary to promote an efficient electrochemical reaction. The anode preferably has vertical slots which are effective in 3s pro~oting egress of reaction product from, and suffi-.
~L28~335 cient electrolyte flow into and through, the gap or space between the anode and cathode to retard accumu-lation of reaction products therein. The anode may be separated from the cathode by a distan oe of about one-sixteenth inch to about two inches apart. A
preferred distance is about one-sixteenth inch to about three-eighths inch, more preferably about one-eighth inch to about three-eighths inch, and a most preferred distance is about one-eighth inch to about one-quarter inch, for advantageous efficiency without undue shortening of useful operatin~ time because of accumulation of electrochemical reaction product. In a preferred embodiment, the anode plate is shaped so that scrap is minimized when the anode plate is cut.
In a preferre~ embodiment, the anode weighs about one-half pound. The anode plate is essentially a rectangular shape with a narro~ arm extended from one long side of the rectangle, and an indentation, simi-lar in shape to the narrow arm, opposing the narrow arm and indenting the anode plate fro~ the opposite lonc side.
The cavity positioned bel ~ the anode-cathode pair has sufficient capacity to contain electrochemi-cal reaction product generated during battery use.
2s By rem~ ing the reaction product from the area sur-rounding the anode-cathode pair, internal resistan oe is minimized and the electroche~;ical reaction pro-ceeds efficiently. The presence of the cavity allows batteries of the present invention to have extended reaction activity.
The battery powered light source is activated by filling each chamber to a ~,uitable level with a saline solution or other aqueous electrolyte. Liquid electrolyte useful in the present invention may be any one of those electrolytes commonly used in batte-~733S
ries. The liquid electrolyte is water containing ~n additive to enhance electrical conductivity. The addi-tive may be sodium chloride r potassium chloride, ammoni-um chloride, sodium hydroxide, potassium hydroxide or s ammonium hydroxide. Sodium chloride is preferred be-cause it is relatively convenient and inexpensive.
Each hou6ing of the present invention ha~ a vertical wall having an interior side facing the cham-ber. The source includes means to support each anode in its respective chamber comprising one or more platforms which project from the interior side of the vertical wall of the housing and form flat horizontal surfaces on which the anode rests. An activated carbon plate is glued to the interior side of the vertic21 ~all to form the cathode. Each housing co~prises two electrically nonconductive shells having vertical edges joined to form a vertical seam. Joining shells to form a vertical seam is an efficient, cost-effective manner of construc-ting the housing. Use of expensive large-cavity molds is not necessary when the housing is constructed by joir,ing edges of two shells formea fron, shallow molds.
In a preferred erbodiment of the present inven-tion, the ~ttery powered light source has means to control air fl ~ into the common air p~ssage or passa-ges. Control of air flow is important in minimizing water evaporation which might reduoe the extent of the electrochemical reaction and hence the life of the battery In another embodiment of the present invention, the battery powered 1ight source has means to alternate-ly halt and recommen oe the electrochemical reaction.
Thus, the life of a battery of the present invention having anode, cathode, and electrolyte to provide power sufficient to emit light of an intensity of 0.9 candela to a distance of one mile from a light bulb continuously 3~287335 or about 28 days may be extended if said ~ttery pow-ered light ~o~ ce has mean~ to alternately halt and recommence the electrochemical reaction. Ihe ~ean~ may be a ~witch such as a manual ~witch or a ~olar switch.
Referring to the drawings, the invention is ill~s-trated as embodied in a barge light device 10 comprising two essentially identical metal/air cell~ lla and llb and a cap member 12 shaped to provide a seat 14 for mounting an electrically ener~izable light sour oe (not shown), e.g. an incandescent or other lamp, in a posi-tion such that the lamp projects above the cap member.
The two cells and the cap are suitably glued or other-wise bonded togethe! to constitute an effectively unita-ry structure.
ach cell has a housing constit~ted of two facing, pan-shaped, molded plastic elements 16 and 18 glued or other~ise bonded together at their facing rims in a continuous sealed joint or seam 20 so as cooperatively to define a generally rectangular chamber 22 for holding a liquid electrolyte. The elements 16 and 18 respec-tively have ~iajor verti~l walls 24 and 26, each extend-ing from top to botto~ and from end to end of the cell, disposed in qenerally parallel, spaced relation to each other, thereby to serve respectively as the outer and inner walls of the cell. Wall 26 is formed with an upper portion 26a having a large rectangular opening 28 across which extend a plurality of mullions 30; this portion 26a is rec~ssed, from end to end of the cell, with respect to the wall portions 26b and 26c respec-tively above and below it. In the assembled device 10, the walls 26 of the two cells lla and llb are adhered together in facing contiguous relation to each other with their respective recessed portions 26a in register, forming a common laterally confined air passage 32 extending horizonally bet~een, and open at each end of, the cells.
Ihe wall portion 26c of each cell may be formed with a horizontally spaced pair of respectively convex and concave dimples 26d for mating with the correspon-ding dimples of the other oell to facilitate assembly of the device. At the top of each cell housing element 16 there is provided a port 16a, closed by a plug 16b, for introduction of liquid electrolyte to the chamber 22;
the plug may have a perforation or other vent opening (not shown) for release of gas generated by electroly-tic reaction within the cell.
Within the element 18 of each cell lla or llb, an air cathode 34 and a suitable metal (e.g. aluminum or alu~,inum alloy) anode 36 are disposed in facing, para-llel, more or less closely spaced relation to each other lS (so as to define an anode-cathode gap G between themJ
with their facing surfaces exposed for contact with liquid electrolyte (not shown) in the chamber 22 of the cell. The air cathode is conveniently a generally rectangular sheet member fabricated of activated car-bon, incorporating an electrically conductive material such as ~ire mesh; it is dimensioned and positionea to extend entirely over the opening 28 ~ith its edges sealingly adhered to the interior surface of wall 26 all around the periphery of the latter opening so as to com-plete the liquid-tight enclosure of chamber 22, being supported externally by the mullions 30. Thus, while one major surface of the air cathode is exposed to liquid electrolyte within the cell, the other major surface of the air cathode is exposed (through the opening 28) to air in the air passage 32. The ~,etal anode is a flat, generally rectangular metal plate of substantial thickness having a plurality of elongated vertical slots 36a opening through its major surfa oe s, and is supported at its lower edge on (and adhered to) a horizontally spaced pair of luglike projections ~8 molded in the wall 26.
~7335 At its top edge, the air Gathode 3~ ha~ ~ vertical-ly extending tab 34a projecting upwardly through a slot 40 in the top of the houfiing element 18. Similarly, the metal ~node 36 has a tab 36b projecting upwardly through a slot 42 in the top of the same housing element. In the assembled cell, a suitable sealing material is applied to close the slots around the tabs, and lead wires (not shown) are respectively secured to the ex posed tab extremities above the housing element. ~or convenience and economy of manufacture, the metal anodes may be cut or punched in sucoe ssion from an extended body of aluminum plate, with the tab 36b of each anode cut out of the body of the anode ahe2d of it, leaving a vertical notch 36c in the lower portion of the anode body.
The dimension and dicposition of the opening 28, air cathode 34, metal anode 36 and luglike projections 38 in each oell are chosen such that the lo~er edges of the cathode and anode are spaced substantially above the floor of the chamber 22. Consequently, each chamber 22 includes a cavity or reservoir portion 22a of subctan-tial volume entirely below the cell el~ctrodes, exten-ding directly beneath the anode-cathode gap of the cell as well as outwardly thereof. This reservoir portion, at least equal in horizontal cross-sectional area to the upper (electrode-containing) portion of the chamber, has a vertical extent (bel ~ the electrodes) that may be as much as one-third, or even more, of the entire vertical extent of the chamber.
The cap member 12 is a unitary, integral, molded plastic body, disposed above and extending entirely over the tops of the two cell housing ele~ents 18 in the assembled device 10, thereby to enclose the tabs 34a, 36b and associated lead wires of both cells. Lateral flange portions 12a of the cap member respectively extend outwardly of, and in contiguous parallel relation to, the top portions of the ~eams 20 of the two oells, and are adhered thereto, while end flange portions 12b of the cap member ~ubstantially complete the enclosure S of the electrode tabs and lead wires.
Before the cap member is bonded to the cells lla and llb, the lead wires are connected between the cells and to terminals tnot shown, but disposed within, i.e.
under, the cap member) of a light source mounted in the cap member seat 14, so as to connect the cells and light source in a series circuit. These electrical connections are isolated from the cell interiors by the abovedescribed sealing of the slots 40 and 42 and are protected by the cap member when the latter is adhered to and over the cells 112 and llb. The light source is supported by and projects above the cap mount 14 to provide ~esired illumination.
In use, the device 10 may be activated by filling the chambers 22 of the two cells with salt water (e.g.
sea ~ater) or other appropriate electrolyte through the ports 16a, which are then closea; alternatively, if the device is provided with a ~ itch (not sh ~ n) in the aforementioned circuit, it may be prefilled with elec-trolyte and turned on by operation of the switch.
Ascuming proper selection and configuration of the light so~ ce, and appropriate dimensioning of the cells and their electrodes lall matters readily ~ithin the ordina-ry skill of the art, given the foregoing description), a barge light designed to ~eet Coast Guard standards and having an advantageously long service lifetime is there-by provided. Reaction product such as aluminum hydr-oxide, formed in the anode-cathode gaps of the cells, passes downwardly from that gap and from the anode slots into the cavity or reservoir portion 22a of each cell chamber; the capacity of these cavities is ~uch as to '.
~l~87;33S
enable extended operation before the accumulatin~ reac-tion product significantly interferes ~ith cell opera-tion. Air flows through the common lateral pa~sage 32 defined ~tween the cells, to permeate the air cathodes as required for the cells to operate, but because this passage is laterally confined bet~een the two cells, the flow of air is limited or controlled, as desired to minimize evaporation losses of the liquid electrolyte in the cells. The device is ~imple and inexpensive yet sturdy and reliable in construction, and is easy to manufacture, assemble and use.
It is to be understood that the invention is not limited to the features and embodiments hereinabove specifically set forth but may be ~rried out in other ways without departure from its spirit.
Claims (20)
1. A battery powered light source comprising:
(a) an electric light bulb;
(b) a plurality of air cathodes;
(c) a plurality of metal anodes, one for each cathode;
(d) a plurality of electrically nonconduc-tive housings disposed adjacent to each other (e) wherein each housing encloses a respec-tive chamber for holding liquid electro-lyte, said chamber containing one cath-ode and one anode which are spaced from each other and form an anode-cathode pair, for electrolytic reaction with said electrolyte producing an insoluble reaction product, each said housing further defining a cavity below the anode-cathode pair and in fluid flow communication with the chamber for col-lecting said reaction product, and each housing has means defining at least one air passage from its chamber to the chamber of an adjacent housing, and an opening through which a surface of the cathode contained in the housing is exposed to air in said passage;
(f) the housings being secured to each other such that said air-passage-defining means cooperatively define at least one common air passage; and (g) circuit means for electrically connec-ting the anode-cathode pairs to each other and to the electric light bulb.
(a) an electric light bulb;
(b) a plurality of air cathodes;
(c) a plurality of metal anodes, one for each cathode;
(d) a plurality of electrically nonconduc-tive housings disposed adjacent to each other (e) wherein each housing encloses a respec-tive chamber for holding liquid electro-lyte, said chamber containing one cath-ode and one anode which are spaced from each other and form an anode-cathode pair, for electrolytic reaction with said electrolyte producing an insoluble reaction product, each said housing further defining a cavity below the anode-cathode pair and in fluid flow communication with the chamber for col-lecting said reaction product, and each housing has means defining at least one air passage from its chamber to the chamber of an adjacent housing, and an opening through which a surface of the cathode contained in the housing is exposed to air in said passage;
(f) the housings being secured to each other such that said air-passage-defining means cooperatively define at least one common air passage; and (g) circuit means for electrically connec-ting the anode-cathode pairs to each other and to the electric light bulb.
2. A battery powered light source as in claim 1, wherein the bulb is a fluorescent, strobe, flash light or incandescent bulb.
3. A battery powered light source as in claim 1, including a lens associated with the bulb, wherein the bulb and lens are capable of emitting light of at least 0.9 candela.
4. A battery powered light source as in claim 1, including a cover surrounding the bulb to direct light from the light source in a generally horizontal direction.
5. A battery powered light source as in claim 1, wherein the air cathode is formed using a porous carbon plate.
6. A battery powered light source as in claim 1, wherein said metal is selected from the class consis-ting of aluminum, magnesium, and alloys thereof.
7. A battery powered light source as in claim 1, wherein the metal anode is a plate having one or more slots.
8. A battery powered light source as in claim 1, wherein the anode and the cathode of each pair are separated by a distance of about one-sixteenth inch to about two inches apart.
9. A battery powered light source as in claim 1, including means formed in each said housing for sup-porting the contained anode entirely above said cavi-ty.
10. A battery powered light source as in claim 1, wherein said anode and cathode cooperatively define a gap opening directly downwardly into said cavity.
11. A battery powered light source as in claim 1, wherein the liquid electrolyte is water containing an additive to enhance electrical conductivity.
12. A battery powered light source as in claim 11, wherein the additive is sodium chloride, potas-sium chloride, ammonium chloride, sodium hydroxide, potassium hydroxide or ammonium hydroxide.
13. A battery powered light source as in claim 11, wherein the additive is sodium chloride.
14. A battery powered light source as in claim 1, in which each housing has a vertical wall having an interior side facing the chamber, and the source includes means to support each anode in its respec-tive chamber comprising one or more platforms which project from said interior side of the vertical wall of the housing and form flat horizontal surfaces on which the anode rests.
15. A battery powered light source as in claim 1, wherein each electrically nonconductive housing com-prises two electrically nonconductive shells having vertical edges joined to form a vertical seam.
16. A battery powered light source as in claim 1 wherein said common air passage is open-ended and laterally confined between passage-defining wall portions of adjacent housings, said portions having said openings through which said cathode surfaces are exposed to air in said passage.
17. A battery powered light source as in claim 1 having means to indicate when intensity of light emitted from the bulb is below a predetermined level.
18. A battery powered light source as in claim 1 having means to alternately halt and recommence the electrochemical reaction.
19. A battery powered light source comprising:
(a) an electric light bulb;
(b) two air cathodes;
(c) two metal anodes, one for each cathode;
(d) two electrically nonconductive housings disposed adjacent to each other;
(e) wherein each housing encloses a respec-tive chamber for holding liquid electro-lyte, said chamber containing one of the cathodes and one of the anodes spaced from each other and forming an anode-cathode pair for electrolytic reaction with said electrolyte producing an in-soluble reaction product, said housing further enclosing a cavity below the anode-cathode pair and in fluid flow communication with the chamber for col-lecting said reaction product, and each housing has means defining at least one air passage from its chamber to the chamber of the adjacent housing and an opening through which a surface of the contained cathode is exposed to air in said passage;
(f) said two housings being secured to each other such that said air passage-defin-ing means cooperatively define a latera-lly enclosed and open-ended common air passage; and (g) circuit means for electrically connec-ting the anode-cathode pairs to each other and to the electric light bulb.
(a) an electric light bulb;
(b) two air cathodes;
(c) two metal anodes, one for each cathode;
(d) two electrically nonconductive housings disposed adjacent to each other;
(e) wherein each housing encloses a respec-tive chamber for holding liquid electro-lyte, said chamber containing one of the cathodes and one of the anodes spaced from each other and forming an anode-cathode pair for electrolytic reaction with said electrolyte producing an in-soluble reaction product, said housing further enclosing a cavity below the anode-cathode pair and in fluid flow communication with the chamber for col-lecting said reaction product, and each housing has means defining at least one air passage from its chamber to the chamber of the adjacent housing and an opening through which a surface of the contained cathode is exposed to air in said passage;
(f) said two housings being secured to each other such that said air passage-defin-ing means cooperatively define a latera-lly enclosed and open-ended common air passage; and (g) circuit means for electrically connec-ting the anode-cathode pairs to each other and to the electric light bulb.
20. A battery powered electricity source compri-sing:
(a) a plurality of air cathodes;
(b) a plurality of metal anodes, one for each cathode;
(c) a plurality of electrically nonconduc-tive housings disposed adjacent to each other;
(d) wherein each housing encloses a respec-tive chamber containing one cathode and one anode which are spaced from each other and form an anode-cathode pair and also encloses a cavity which is below the anode-cathode pair and is in fluid flow communication with the chamber, and each housing is capable of containing electrolyte which promotes an electro-chemical reaction in said chamber and cavity and each housing has means defin-ing at least one air passage from its chamber to the chamber of an adjacent housing, and an opening through which a surface of the contained cathode is exposed to air in said passage;
(e) said housings being secured to each other such that said air-passage-defin-ing means cooperatively define at least one common air passage; and (f) circuit means for electrically connec-ting the anode-cathode pairs to each other.
(a) a plurality of air cathodes;
(b) a plurality of metal anodes, one for each cathode;
(c) a plurality of electrically nonconduc-tive housings disposed adjacent to each other;
(d) wherein each housing encloses a respec-tive chamber containing one cathode and one anode which are spaced from each other and form an anode-cathode pair and also encloses a cavity which is below the anode-cathode pair and is in fluid flow communication with the chamber, and each housing is capable of containing electrolyte which promotes an electro-chemical reaction in said chamber and cavity and each housing has means defin-ing at least one air passage from its chamber to the chamber of an adjacent housing, and an opening through which a surface of the contained cathode is exposed to air in said passage;
(e) said housings being secured to each other such that said air-passage-defin-ing means cooperatively define at least one common air passage; and (f) circuit means for electrically connec-ting the anode-cathode pairs to each other.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US915,815 | 1986-10-06 | ||
| US06/915,815 US4745529A (en) | 1986-10-06 | 1986-10-06 | Battery powered light source |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1287335C true CA1287335C (en) | 1991-08-06 |
Family
ID=25436291
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000548494A Expired - Fee Related CA1287335C (en) | 1986-10-06 | 1987-10-02 | Battery powered light source |
Country Status (10)
| Country | Link |
|---|---|
| US (1) | US4745529A (en) |
| EP (1) | EP0263683B1 (en) |
| JP (1) | JPS63114080A (en) |
| KR (1) | KR880005700A (en) |
| AT (1) | ATE70387T1 (en) |
| AU (1) | AU589101B2 (en) |
| CA (1) | CA1287335C (en) |
| DE (1) | DE3775160D1 (en) |
| ES (1) | ES2027298T3 (en) |
| IN (1) | IN171246B (en) |
Families Citing this family (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA1276972C (en) * | 1986-10-22 | 1990-11-27 | David S. Strong | Multi-cell metal/air battery |
| GB2211016A (en) * | 1987-10-15 | 1989-06-21 | Wong Chau Patrick Cham | Deferred action cell |
| US4926300A (en) * | 1989-03-13 | 1990-05-15 | Key Industries, Inc. | Disposable flashlight with improved activator field of the invention |
| JPH06501128A (en) * | 1990-09-18 | 1994-01-27 | アルカン・インターナショナル・リミテッド | aluminum battery |
| US5024904A (en) * | 1990-11-01 | 1991-06-18 | Envirolite Products, Inc. | Direct current salt water activated generator |
| RU2102822C1 (en) * | 1995-11-13 | 1998-01-20 | Товарищество с ограниченной ответственностью Научно-производственная фирма "Рико" | Metal-air chemical current supply |
| US5963009A (en) * | 1998-03-27 | 1999-10-05 | Brotherson; Gaylen M. | Salt water power source and lantern |
| KR100669200B1 (en) * | 2004-05-24 | 2007-01-15 | 주식회사 미트 | Marine rescue flashlight |
| JP6199028B2 (en) * | 2012-12-18 | 2017-09-20 | 日本協能電子株式会社 | Air magnesium battery |
| JP5559927B1 (en) * | 2013-12-25 | 2014-07-23 | 日本協能電子株式会社 | Air magnesium battery |
| JP6761638B2 (en) * | 2015-02-04 | 2020-09-30 | 株式会社半導体エネルギー研究所 | Rechargeable battery |
| CN105605458A (en) * | 2016-02-25 | 2016-05-25 | 台州非常新能源科技有限公司 | Water-activated LED lamp |
| CN106532193A (en) * | 2016-11-30 | 2017-03-22 | 金华市潜龙新材料科技有限公司 | Water injection power generation camping lamp |
| WO2022259027A1 (en) * | 2021-06-10 | 2022-12-15 | German Munenobu Nagahama Schell | Water lamp |
Family Cites Families (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2207734A (en) * | 1936-06-27 | 1940-07-16 | Nat Carbon Co Inc | Electric cell |
| FR1444088A (en) * | 1965-05-17 | 1966-07-01 | Wonder Piles | Improvements in electrochemical devices, in particular batteries |
| US3457115A (en) * | 1965-12-03 | 1969-07-22 | Gen Electric | Gas-depolarized electrical power unit with filter means |
| US3403249A (en) * | 1965-12-22 | 1968-09-24 | Union Carbide Corp | Battery powered signal unit |
| US3533845A (en) * | 1967-01-27 | 1970-10-13 | Leesona Corp | Low-current,low-capacity metal/air battery |
| FR1539952A (en) * | 1967-08-11 | 1968-09-20 | Wonder Piles | Advanced training in electric batteries |
| US3539396A (en) * | 1968-11-05 | 1970-11-10 | Us Army | Rechargeable alkaline zinc system |
| FR2153668A5 (en) * | 1971-09-20 | 1973-05-04 | Cipel | Battery electrolyte immobilisation - using acrylamide and methyl-n,n-bis-acrylamide copolymerised |
| US3914813A (en) * | 1974-09-18 | 1975-10-28 | Yardney Electric Corp | Emergency light means |
| GB1489576A (en) * | 1974-12-20 | 1977-10-19 | Electric Power Storage Ltd | Metal air batteries |
| JPS5850615Y2 (en) * | 1977-04-04 | 1983-11-17 | 古河電池株式会社 | floating metal-air battery |
| FR2469011A1 (en) * | 1979-11-05 | 1981-05-08 | Thomson Csf | Seawater activated battery |
| US4626482A (en) * | 1985-11-18 | 1986-12-02 | Alupower, Inc. | Metal/air batteries |
-
1986
- 1986-10-06 US US06/915,815 patent/US4745529A/en not_active Expired - Fee Related
-
1987
- 1987-10-02 CA CA000548494A patent/CA1287335C/en not_active Expired - Fee Related
- 1987-10-05 AU AU79357/87A patent/AU589101B2/en not_active Ceased
- 1987-10-06 KR KR870011280A patent/KR880005700A/en not_active Withdrawn
- 1987-10-06 JP JP62253457A patent/JPS63114080A/en active Pending
- 1987-10-06 AT AT87308859T patent/ATE70387T1/en active
- 1987-10-06 IN IN879/DEL/87A patent/IN171246B/en unknown
- 1987-10-06 ES ES198787308859T patent/ES2027298T3/en not_active Expired - Lifetime
- 1987-10-06 EP EP87308859A patent/EP0263683B1/en not_active Expired - Lifetime
- 1987-10-06 DE DE8787308859T patent/DE3775160D1/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| EP0263683A3 (en) | 1989-03-08 |
| IN171246B (en) | 1992-08-22 |
| ATE70387T1 (en) | 1991-12-15 |
| ES2027298T3 (en) | 1992-06-01 |
| AU589101B2 (en) | 1989-09-28 |
| EP0263683B1 (en) | 1991-12-11 |
| EP0263683A2 (en) | 1988-04-13 |
| AU7935787A (en) | 1988-04-14 |
| KR880005700A (en) | 1988-06-30 |
| DE3775160D1 (en) | 1992-01-23 |
| JPS63114080A (en) | 1988-05-18 |
| US4745529A (en) | 1988-05-17 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA1287335C (en) | Battery powered light source | |
| US5487955A (en) | Cooled zinc-oxygen battery | |
| US4925744A (en) | Primary aluminum-air battery | |
| CN86107892A (en) | Surfactant flooding system | |
| US3963519A (en) | Metal/air cell | |
| EP2819237B1 (en) | Air cell | |
| US5049457A (en) | Electrolyte for an aluminum air-battery comprising an anti-foaming agent and corrosion exhibitor | |
| JPH11514137A (en) | Air management system to reduce air concentration in metal-air batteries | |
| US5225291A (en) | Deferred actuated battery assembly | |
| US3914813A (en) | Emergency light means | |
| EP0509064B1 (en) | Direct current salt water activated generator | |
| US4184008A (en) | Float type metal-air battery | |
| US5116695A (en) | Deferred actuated battery assembly system | |
| KR20210087223A (en) | A seawater battery in use with independant cathod type | |
| RU2008142472A (en) | SOURCE OF ELECTROCHEMICAL ENERGY | |
| US3497388A (en) | Hybrid gas-depolarized electrical power unit | |
| US5286578A (en) | Collapsible electrochemical cell assembly and battery assembly comprised of a plurality of collapsible electrochemical cells | |
| EP3966887B1 (en) | Nested annular metal-air cell and systems containing same | |
| US3489613A (en) | Battery comprising an alkali metal superoxide cathode | |
| US3589945A (en) | Stacked metal gas-cells | |
| CN221304826U (en) | Knob-started aluminum-air emergency power supply | |
| RU86049U1 (en) | PORTABLE AUTONOMOUS ELECTROCHEMICAL CHARGING DEVICE | |
| SU752566A1 (en) | Air-magnesium cell | |
| CN208570870U (en) | A kind of basket type metal fuel battery | |
| CN107579187A (en) | A kind of anti-electrolyte percolated metal fuel cell |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKLA | Lapsed |