GB2398424A - Rechargeable cell system - Google Patents

Abstract

A cell system, wherein at least one pattern designed single anode cell and at least one pattern designed single cathode cell are connected in a serial arrangement, said cell system comprising at least due set serial connected cells oriented along a web 1 and at least a part of at least one said set serial, arranged cell immersed in an electrolyte 9. The current generated may be employed in vehicle electrical propulsion systems.

Description

- . . . . À - . RECIIAR(,F,ABLF, (F.LI, SYSTEM HACK(,ROUND OF'I'HI'I

INVENrl'lON I'hc present invention is directed to an electrochemical process gencrathly a hip,h-ratc current for powering an electrical motor in a modern auto'nQhile Or up t l()()() km. 'I'he new electrochcnical cell system can he recila)g,etl every.()()t) knit.

I'he slate ol' the art electrochemistry dot'S not include a reliahic method of releasing, stored e iectrieal energy in an electrolysis process.

I'he proton exchange membrane t'uel cell (I'I..M('C) is one ol' tire most promishig technologies. Ior hew hut very serious reasons, it is.nlikcly that the I'l-.Mt*'C technology will find its way to the market place any thee soon. 'I'he required operational lilelimc for the 1'1-<2MIC is 5,()() 0 hours. I.Icctrocilemical corrosion ol'tilc metallic components in the feel cell occurs al a I:ar earlier static than S.()()() operating hours. I-lig;h corrosion resistance and electrical conductivity rcquircnets lor l'ucl cell conponcuts. however, preclude most uncoated metals l'rcm use. (it rrosi()n resistant alloy coatings and conductive polymer coatings for bipolar I'ISMI;'( plates have nisi been able lo reach a staLge where any developments can be commercialized. Many claim to have developed a reliable method. but there are still many unansxeretl questions. I'ron1 what is known thus l'ar' lhcrc are still corrosion and conductivity material property rccluirements needed in the electrolysis process which have not heen resolved. However, the most serious problem is the dang;cr ol'an cxpksion as a result oJ'an accident or a terrorist activity. (fine can only inagc what will happen if an explosion occurs in a parking, garage with hundreds ol' ears parked close Kit each other and a chair1 ol' singic explosions take place. 50()()psi hydrogen (sornc arc thinking about making hydrogen tanks for lO()OOpsi) is highly explosive' dillicull to store/distribute, and can be very dangerous. It is only a rrrattcr ol'limc hcicre the first Pl.MI;(' powered automobile will explode in a collisions like a borne, with the result that one or more individuals will die hista',taneously. 'I'his situation canriol he avoided, no maticr how many safety precautions are eng,iileerecl into the 1'12MI(' powered automobile. When the public learns of' the first accident, he or she will À t À C c. a e eee e ee.

ec. ce. e decide not to purchase a PEMI C powered automobile. 11' a gasoline tam; in a traditional automobile starts to burn as a result ot' a collision, tile operator and the passengers have only a very short lime to escape before a 1'ire-blast eventually occurs.

I'he l't2MI'(' powered automobile will also be tar too expensive lor the average consulllcr.

I'he ll'ME'( cell requires hydrogen which is not readily available. thing a rcl'-.'rmer to turn hydrocarbons car alcohol into hydrogen produces heat anal otilcr gases which will pollute the environment. 'I'he overall et'ticiency of the l'l'MI*'(' powering an electrical molar h1 an automobile is about 25 to 31 percent. which is very low.

I'he l'l:MI''( receives to much incorrect public niedia attention. '['his indignation does not claril'y the high energy consumption for produeirlp, hydrogen, the higl1 cost. public safety, and how such a conversion process will pollute the environment.

battery powered electrical automobiles have a very high et'lciency. 'I'he battery is about 9() percent el't'ieient anal the electrical motor/invertel is about <3() percent eilieient. 'I'his gives an overall et'l'iciency of' ahotlt 7o percent which is considered very good, but state ot' the art battery tcchnolog,y has insul'l'icicnt capacity lor the modern automobile.

I'he ct'l'iciency ol'the gasoline driven automobile with a combustion engille is very low, olily 20 percent. 'I'hat is, only about 2() percent ,I'tht theroval-cnerg,y conical ol' tile gasoline is converted into mechanical work. I lowcvcr, the combustion cnginc can be considered practical and economical tor lack ot'arioliler alternative. From an environmental point of view, the combustion eng,inc is devastating to the global environment. From a human lealtl1 point ol'\iew, the combustion eng,inc is eventual!) the most serious man-made health concern in rmotlen limes. Automobiles with combustion cng,ines make life much easier for many individuals and is. perhaps the reason why the environment and health problems have been ovel shadowed for so long, a time. 'I'he air has been heavily polluletl in many world witle metropolitan areas lot a long perioLl of time. As a result o:t'thc high level of air pollution many intli\iduals have serious lil'c time health problems. I ligh concentraliolis ol'carhor1 morioxile (('1)) in cities whelc automobiles operate at higl1 density means float the human heart has to work hartler lor the oxygen displaced how the blootis hemoglobin by Cal bon monoxide. It is tar more complex to proof' that carbon monoxide causes the disecise À À . À À . c Ace À asthma. A whole range ot'f'actors are involved. Several ot'the involved factors are pointing in the direction ol'the asthma. In the tJnitcd States alone, 17 million pole, including 4 million children, have been diagnosed with asthma.

I'he sheer quantity ol' carbon dioxide ((()2) emitted in the combustion engine process is increasing the concentration of' carbon dioxide in the atniosptlerc and enhancing the greenhouse ef'f'eet. Polluted air has also caused several other health and environmental problems.

The Zero emission vehicle (7,12V) will he a major factor in restoring, the environment and provide generations to come with hefter health.

I'he lead-acid cell has two interesting f'e'tures. 'I'hc reaction is completely reversibility (for some ceil designs, reversible up to 3()()4()0 hundred tickles). the characteristic voltage is 2V per cell (a high voltage per cell compared with sonic ceils designs Wittl other material combinations).

Automobiles powered with an electrical motor powc red by lead-acid ceils arc considered to be ZI-.V vehicles.

I'here are two methods of'manuf'acturirig lead and lead oxide grid plates used in current lead-acid cells. 'I'he most common method uses two separate vertically oricilted mold panels. Itespective bottom. sides and partially top of both mold puncis calves are contact each ottler in a closed engagement. stormings the grid plate nold cavity. I Fluid Iead (melting point 37 5 (1) is poured hits the mold cavity Lion the renahling top opening. Liquid Iead reaches the Cottons of'tilL entire mold cavity by gravity before l'ree:<h,. For preventing the melted lead liom l'ree'.ing hel'ore reaching the entire mold cavity a cork insulation solution is sprayed inside both mold panel walls. 'This layer does not last f'or very long and has to be removed and applied over again about every 4 hours which is not very praelical. Air-veriting the mold cavil\: during liquid lead filling is another problem. 'I'his manul:acturing nelilod is not considered to be very sophisticated. 'I'he second lead grid manufacturing nethod is nature developed l'rom a manufacturing point ol'view. A cylindrical rotating drum has a surface pattern identical to the ready east grid plate. I cad is melted in a stationary shoe (melting pot). oriented at the top area of the rotating drum. Ids the drum continuously rotates' melted lead from the shoe flows into the drums surface grid pattern. When the melted Icad passes the shoe wall's lower Font cdprc oriented À À À c straight across and with a close tolerance to the drum surface, melted access lead is held back by th, walls lower edge. 'I'he lead in the drum surface patient then i'reees to a continuous grid. 'he drum surface has slightly lower temperature than the lead shoe and a continuous frozen grid web can now easily be rcmo\ed i'rcm the drun1 surface.

I-he grids are rolled to a more narrow gauge in a separate naehine, hellfire pasted.

I'he preparation ol' the active material precursor consists oi'miXhg and curing operations using ready lead oxide (PLO I'b), sullluie acid. and water. fiche ratio ol' the reactants and curing conditions (Iernperalure humidity, and tinge) al'lect the development of crystalline and pore structure. 'I'he cured plates consist ol' lead s.llale.

lead cxicle, and some residual lead ( 5 /o). I'he positive active material, which is l;'rmet cieetrochemieally prom the cured plate, is a major factor inilueneing the performance and lily oi the icad-aeid cell. In general, the negative, or lead, electrodes control eold-temperature performance. 'I'he electrolyte is sult'urie acid. typically having a specific gravity ot'ahout 1.2X.

I'he industry believed for many years that cured paste having micro erases did diminish the ceil capacity. Long term testing has proven this t.heoy wrong.

hi general; heavy plate gauge Favors deep-cycle capacity, narrow plate gauge and large plate surface area increases the hip,h-rate capacity. For powering a modern automobile powered by an electrical motor, typically high-rate capacity is required most of the time.

I'he research and development ol' this new electrochemical ceil process introduced endless considerations in the llelds oi'physies and chemistry.

Imnersing a pasted led and lead oxide cell structure in dilute sult;'rie acid. one cell structure immersed and next cell structure immersed first after the previous ecil has been partially discharged. I'artially two or more cells structures in a eleetroehcnical reaction at the sanlC thee, with a eontinuinL; long chain, of' separate non conductive but eonneeting, cells, lollowirlp in separate double ceil rcaclions. As a cell diseharg, e, both grid layers build up lead sulfate (lbbi()4) and water builds up in Else acid. Sulturic acid supply from a reservoir is therefore needed, as the chain, ol multiple reactions proceeds.

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SUMMARY OF THE INVENTION

Accordingly, it is an object ot'the present invention to obviate the above-noted shortcoming and disadvantages of'wireless mobile power units known h1 prior art.

It is another object of' the present invention to provide a cell system which will he more economical.

It is another ob feet of the present invention to prOViLle a cell system whiel1 will preserve the environment in a better way.

It is still Further object of' the present hivention to provide a cell system whic will reduce human health concerns.

It is another objective of' the present invention to provide a ceil system which will reduce the consumption of' natural resources.

After inveslig,ating and testing large numbers ol'dit'l'erent materials. glass fiber seem to have the best material characteristics t'or following web application; A non woven glass fiber web will be used as a web carrier For the pasted narrow-gauged lead and lead oxide connecting: grid patterns. During the lead application pTX)CCSS the' n<,n Woven glass f'iLer web will be exposed to 33()''(.'. A glass -lither web having cross oriented fibers (non woven pattern)' narrow,augc ( 11g,in2) bonded by 2-. 'i"'o polyvinyl alcohol (I'V011) binder, was tested in a nuf'l1cr furnish. 'lathe material ignited at X15 ('. PVOII has a melting Cohn at 34. ('. ([lass has a knelling point at 1 2()()"(' . I+'r-,r applying the lead/lead oxide layer, (().14mm gauge), grid pattern lo a glass l'iber non woven web, a modified version of' above mentioned second grid manut:acturing method is used. A rotating cylinder (internally liquid chilled) is h1stalled in the existing shoe wall mold area, in between whicl1 the glass fiber non woven web and the grid lead pattern interfaces. 'I'he lead shoe has a divided manif'oltl with separated, multiple lead and multiple lead oxide compartment outlets. 'lathe glass fiber Iron woven web surface area is air cooled with nulliple air noz.z.les whets passing the drun1 surl'ace section. rl'he lead grid pattern then Freezes onto the nexus woven glass filer web, and the non woven web including the iced grid pattern can thereafter easily be removed f'rom the drum surl;ace. 'I'he led coaled non \V(1VCn will be con\eyed to an h1 Ih1e pasting drum unit. 'I'he paste drum has a multiple line paticrn across the with.

which remain unparted. Stale of' the aid photo-electric servo nolor wet, guidh1g À À c.

À c À À À À À À À system, adapted from a printing press, easily position the paste pattern in correct position on the lead coated non woven web.

To prevent multipole interaction when the web is winded Up into a rolls an insulation layer between the active cell layers is therefore required. An extruded l'olypropylene (I'P) film, ().25mm gauge is perloratccl with high density micro passages in a t'irst manufacturing stage. In a second manuf;acturdl stance applying, anti point sealing, (2()points/em2) a Pl' fiber web (..()I)tex- Xmm leers 22/m2) ciirectly from a textile fiber processing machine in line with a rotating heat point sealing unit on one side ol'the perforated 1'1' I'ilm. A large (iennan company have a substantial production capacity of heat point sealed Pl' non woven. which quality is close to what is required for this application. Tile 1'1' hsulation layer will be inplenented from a roll hi line with above mentioned lead antt paste application process.

I-'or automobiles with extra high power requirenents. a multi Layer lamhate cell structure couRl eventually be needed. According to preliminary calculations, tine ceil web layer generates sul'l'icient power for a regular automobile.

I'he two layers are furthermore compressed between compression rollers hmcrsing the insulation layer one side many unsealed 1'1' fiecrs into the paste. It could he necessary to convey the yastcd non woven cell web layer through a short high-tempcraturc heating tunnel lor cstablishhg correct paste moisture content bel'ore compression. 'I'he purpose with the many open 111 i'ibers point sealed to the 1'1' I'ilm is for the fibers to i;:'rm a bond to the paste after curing.

A binclhg site between the surfaces of two dill'crenl molecules did not materialize for this application therefore above bbiding ncthod was dcvelopetl. Many have usCt polymers l-or other applications. Several polymer types have many highly valuable material properties but would have diminished the ceil capacity and redtcel the conductivity l'or this application. 'I'he multi layer laminate ceil structure is now ready lor curing.

Llach ceil grit layer area is divided into 2() serial connected;osilive and negative cells across the web. 'I'hc serial arrancd connected cell principle increases the voltages and is thtrelore the most suitable grid lay-out out principle tor tills application. 'I'his method ol' applying least grid patterns prtdtces inl'inite lay-out pattern options. I'roL; ramming an electrical discharge machine (I.I)M) anti lurnhn: a À À À , 8 À , c,, À new drum surface, will change the grid pattern.

Tile finished pasted and cured lead/lead oxide multi layer laminate ceil vcb is conveyed l'rom a roll through a discharge area in the electrolysis process. Al'ter passe the clischarge area, the cell web is again winded up info a roll. (conveying the cell web from one to another roll, require web side rcinlorcencnt and side,uidancc.

Melted 1'1' will be applied to a specific area al troth web edges by a hot melt Stun. 'I'wo higilly precise and reliable hot-melt systems arc available. 'I'he two' web layers arc then compressed between high temperature resistant, 'I'ellon coaled coriipressiorT rollers.

she melted PP f'reez.es and binds the two cell layers together. In the same area, close to hotl1 sides web edges' a line of circular (5mm diamctcr) passages are puncilcd out lor ever 23mm, in a separate operation. 'I'he multiple passacs matcTlirlp the guide rollers multiple guide pins around the guide rollers periphery, will guide the web.

Above mentioned method of manufacturing a ceil web is only one mctlod armong, several other available manufacturing mctilods t'or applying; lead and printing a paste pattern onto a non woven weld.

Two curTent collector hefts, one oriented on cacti side ot' the cell welt hi the electrolyte area, collecting the respective positive and negative current from the anode/cathode web is immersed in dilute sulfuric acid. I 'or preventing corrosion ol'thc current eollcetor belts, a silver plated copper m-'lyhdeuum alloy bell has heen selected. Silver has best electrical conductivity values ol' all metals. arid electrocilemieal corrosion ol'silver is similar to graphite which is very low. (graphite has suceessl'ully been used as a reliable corrosion barrier in acid batteries lor many years. A spring loaded polyurethane timing belt secure contact between the anode/cathode web and the alloy belt at all times.

About every 3000 km the cell system has to be recharged. 'I'he reasons ally trained personal at a service station should replace a recharged roll, is that every recharged roll has to be washed and air-dried, before Stalled again. ()lherwise, the cell web will selt:discharged al about a rate of ().5-3.'ho each day. Replacing a recharged cell woh roll, will take about the same thee as an oil change in a regular automobile. Recharging the multi laminate ceil web 2()() thnes t'or every l()()() driven km (preliminary, calculated estimates at this stance only!. will provide an automotile whiel1 can be driven 600.()0() km, bel'ore replacing the ceil web. All components l'ron # À ce r 1 À 1 À À À À this multi laminate cell web can be recycled.

IlRIEF'DESCRlPTION OF T111: DRAWINGS leisure 1 is a side view illustrating; the electrolysis process-unit, integrated between the wheelcases in a body profile of a modern automobile design.

I'igure 2 is an isometric view of the ceil web and the current collector hefts from the electrolysis process discharge area.

I''igure 3 is a sectional top view of the ceil web (t'rom figure 2), illustrating the cell webs lead and lead oxide grid lay-out pattern.

DESCRIPTION OF THE PREFERRED F:MIlOI)IMICNT

I'he dry charged cell web contains 15() separate, pasted lead and lead oxide cell structures attached k, a continuous non woven glass fiber web. As the nultipic cell structures diseharL;es. the cell web intermittently tralsf'er prom roller 1 to 13, figure 1.

I'he dry charged anode and cathode cell web unwinds from ceil woh roll 1via guide roller 2 and 3, into sult-'urie acid/electrolyte section ') between walls.S and 1.

I'hc cell webs anode and cathode current gullets, oriented at each side ol'the ceil web, establish contact to each respective sides anode and cathocie current collector hefts.

Both webs sides current collector belts (X), transl'errh1g, the positive charged current to one side and the negative charged current to the other side ol'the current collector (4).

I'he current collector 4 has a mid oriented h1sulalion section. and supply a positive current through one end. and a negative current through the other end, and ftrtherr1lore to an outside converter, eonverth1g the eunent fr-on 1)(' lo AC'. I'aeh cell web sir.ctures eornprising, 20 ceils (4()V 1)(), 1() anotIe and 1() cathode single celix.

All single ceils are connected h1 a serial arrangement, with positive charged web side current outlet 17 and negative charged with side current outlet 1 X. A nor conductive Ih1e-area 16, I'igure 2, is oriented between each cell structure across the web, blocking, the current to flow between all cell web structures. As n1ore than one anode/catl1ode ecil web struclur-e will have contact with the current collector belt al the sane thee, previous and next anode/catl1ode cell web structur;; will be parallel connected via respective sides of current collector belts 15 and I'). l,rlp,aging, more than one cell web structure in the discharge process at the same tine enable the previous cell web À À . À . À À e À structure to he in a late discharged stage. while next cell web structure is in an early discharge stage, providing a continuously stabile power supply. I\s the electrolysis process develops in the electrolyte, water builds up in the electrolyte and the lead sulfate (I'bSO4) builds up on the anode and cathode. When the water content build up in the electrolyte. additional sulfuric acid/electrolyle is pumped l'ron1 tank 7, info multiple passages (j and furthermore into sub passages (A distributing s. ll'uric acid across the entire web s.'rt'ace. Tile elecirolytc/sull'uric acid level is always above electrolyte section lop wall cover 5 and the multiple compartments ') are therefore conpietely filled with dilute sulf'urie acid across tle entire web area at all lines, preventing tle electrolyte l'rom moving when the automobile is moving. I I is current collector belt ease, connected and oriented on boll1 sides ot' the electrolyte section 9.

2,312 and 13 web guide rollers have matching guitles pins lo the cell webs side edge passages. Drawing 3 is section 20 from drawing 2, and is part of single eathotle cell 21 serial connected to part ol' single anode ceil 22 and furthermore serial connected to part ot' single cathode cell 23 having current eollect.,r and web guide passages.

Relerence No. 25 refers to unpasted web joints across tlc entire woh structure. A separate tank -for de-ionized water is needed.

I'he present invention should not be considered limited to the particukir examples described above, but rather should be understood to cover all aspects ot tlc hvcntion as fairly set out in the attached claims. Various modifications equivalent processes, us well as numerous structures to whicl1 the present invention nary he applicable, will be readily apparent to those ol skill in the art to which the present invention is directed upon review of the instant specification. À À a.e

Claims (1)

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   1 ('laim: 1. A cell system, wherein at least one pattern designed single anode cell and at least one pattern designed single cathode cell are connected in a serial arrangement. said ceil system comprising at least one set serial connected ceils oriented along a woh, and al least a part of at least one said set serial arranged cell immersed in an electrolyte.

   2. A cell system according to claim 1, wherein at least two said pattern designed serial arranged ceils sets are discharged in a parallel connected arrangement.

   3. A cell system according to claims I - 2, wherein said anode and said cathode are connected to respective current collectors belts.

   4. /( cell system according to claims 1 - 3. wherein at Ieast one said current collector belt is generally oriented along each edge of said cell web.

   5. A cell system, wherein at least one pattern designed single anode cell and at least one pattern designed single cathode cell are connected in a parallel arrangement, said parallel connected cells arranged in at least two serial connected arrangements along a web, and at Ieast a part of at least one set said serial arranged cell immersed in an electrolyte.

   6. A cell system, wherein at Ieast one pattern designed single anode ceil and at least one pattern designed single cathode cell are connected in a parallel arrangement said parallel connected ceils arranged in at least two serial connected arrangements along a web to outside current collectors, and at least a part of at Ieast one set said serial arranged cell immersed in an electrolyte.

   7. A cell system, wherein at least one pattern designed single anode cell and at least one pattern designed single cathode cell oriented along a web may be connected in any configuration, and a at least a part of said anode and said cathode cell immersed in an electrolyte or gas.

   8. A ceil system according to claims 1 - 7. wherein said anode and said cathode cells are generally pasted.

   9. A cell system according to claims I - 8, wherein said anode ceil consist mainly ol lead oxide and said cathode cell consist mainly of lead.

   1(). /\ ceil system according to claims I - 9, wherein said anode cell and cathode cell may consist of any material or material combination. r À 1

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   11. A cell system according to claims 1 - 10 wherein said anode ceil and said cathode cell react with an electrolyte in an electrolysis process.

   12. A cell system according to claims I - I 1 wherein said electrolyte is dilute sulfuric acid.

   13. A cell system according to claims 1 - 12, wherein said electrolyte could be any chemical or gas.

   14. A cell system according to claims 1 - 13, wherein said anode and cathode cell webs current collector contact area generally remain unposted.

   15. A cell system according to claims 1 - 14 wherein said pasted anode and cathode cell web joints generally remain unposted.

   16. A cell system according to claims I - 15, wherein at least a part of said ceil web comprising an insulation layer.

   17. A cell system according to claims 1 - 16, wherein said anode/cathode cell web comprise more than one layer.

   18. A cell system according to claim 17, wherein said insulation layer is oriented between each said pasted anode/cathode ceil web layers.

   19. A ceil system according to claims 1 - IX, wherein said ceil web are moving intermittently through said electrolyte section.

   2(). A cell system according to claims I - 19, wherein each said set serial connected cells is moving out ol the electrolyte after partially have been discharged.

   21. A cell system according to claims 1 - 2(), wherein each said set serial conucctcd cells is moving out of the electrolyte after havhig generally been discharged.

   22. A ceil system according to clams 1 - 21, wherein at least one oi said anode and said cathode both material patterns molded onto a web.

   23. A cell system according to claims 1 - 21, wherein at least one of said anode and said cathode both material patterns applied to a web by a foreign sealant.

   24. A cell system according to claims I - 21, wherein at least one ol said anode and said cathode both material patterns applied to a web through a binding site provided by a chemical agent.

   25. A cell system according t<> clams 1 - 21, wherein at least one of said anode and said the cathode both material patterns applied by electroplating.

   26. A ceil system according to clahns 1 - 25 wherein said ceil web could be made ol 1 1 À Be # 4 À e. , I, e 4 '44 À À ..

   e À e À À 4 Be.e any material or material combination.

   27. A cell system according to claims I - 26 wherein said ceil web comprising multiple liquid penetrating passages.

   28. A cell system according t o claims I - 27, wherein said cell web comprising, matching guide passages to said guide roller pins.

   29. A cell system according lo claims I - 28 wherein said cell web is divided into at least two separate cell webs.

   30. A cell system according lo claim 29 wherein said separate cell webs have different polarity.

   3 I. A cell system according to claims I - 30. wherein said cell web can be recharged.