Battery resetting process for scaffold fuel electrode

Abstract

An electrochemical cell includes a fuel electrode configured to operate as an anode to oxidize a fuel when connected to a load. The cell also includes an oxidant electrode configured to operate as a cathode to reduce oxygen when connected to the load. The fuel electrode comprises a plurality of scaffolded electrode bodies. The present invention relates to an electrochemical cell system and method of resetting the electrochemical cell by applying a charge (i.e. voltage or current) to the cell to drive oxidation of the fuel, wherein the fuel electrode operates as an anode, and the second cell operates as a cathode, removing uneven distributions of fuel that may cause premature shorting of the electrode bodies to improve capacity, energy stored, and cell efficiency.

What is claimed is: 
     
         1 . A rechargeable electrochemical cell system for generating electrical current using a fuel and an oxidant, the cell system comprising:
 a plurality of modules, each comprising N electrochemical cells each comprising a fuel electrode, an oxidant electrode, a charging electrode, and an ionically conductive medium communicating the electrodes, wherein N is an integer greater than or equal to two; and   a plurality of switches switchable to:
 (1) a discharge mode coupling the oxidant electrode of each cell  1  to N−1 to the fuel electrode of the subsequent cell to couple the cells in a discharging series, such that when the fuel electrode of cell  1  and the oxidant electrode of cell N are coupled to a load, oxidation of fuel at the fuel electrodes and reduction of an oxidant at the oxidant electrodes creates a potential difference within each cell to thus create a cumulative potential difference anodic at the fuel electrode of cell  1  and cathodic at the oxidant electrode of cell N for delivering a current to the load, and 
 (2) a charge mode coupling the charging electrode of each cell  1  to N−1 to the fuel electrode of the subsequent cell to couple the cells in a charging series, such that when the fuel electrode of cell  1  and the charging electrode of cell N are coupled to a power source to receive a charging potential difference cathodic at the fuel electrode of cell  1  and anodic at the charging electrode of cell N, an incremental potential difference is created within each cell to reduce a reducible fuel species at the fuel electrode and oxidize an oxidizable oxidant species at the charging electrode, 
   wherein the plurality of switches are switchable to a bypass mode for a cell (X) of the N electrochemical cells by coupling the charging electrode, in the charge mode, or the oxidant electrode, in the discharge mode, of a previous cell (X−1) to the fuel electrode of a subsequent cell (X+1);   wherein:
 the plurality of switches include a triple throw single pole switch for each cell; 
 a static contact for the triple throw single pole switch for each of cells  1  to N−1 is connected to the fuel electrode of the subsequent cell (X+1); 
 a first selective contact for the triple throw single pole switch for each of cells  2  to N is connected to at least the static contact of the previous cell (X−1); 
 a second selective contact for the triple throw single pole switch for each of cells  1  to N is connected to the charging electrode of the associated cell (X); and 
 a third selective contact for the triple throw single pole switch for each of cells  1  to N is connected to the oxidant electrode of the associated cell (X); and 
   wherein each of the plurality of modules is connected by a charge/discharge control system configured to selectively electrically isolate one or more of the N electrochemical cells within each module through control of the plurality of switches, and selectively electrically isolate each module from one or more other modules of the plurality of modules.   
     
     
         2 . An electrochemical cell system according to  claim 1 , wherein the cells are assembled adjacent one another with a non-conductive barrier separating the oxidant electrode and fuel electrode of each pair of adjacent cells such that the only permitted electrical connection therebetween is via one of the plurality of switches. 
     
     
         3 . An electrochemical cell system according to  claim 2 , wherein each cell is a metal-air cell with the fuel electrode comprising a metal fuel, the oxidant electrode comprising an air cathode for reducing oxygen, and the charging electrode being an oxygen evolving electrode for oxidizing an oxidizable oxygen species to oxygen. 
     
     
         4 . An electrochemical cell system according to  claim 3 , wherein the metal fuel is selected from the group consisting of zinc, aluminum, iron, and manganese. 
     
     
         5 . An electrochemical cell system according to  claim 3 , wherein each non-conductive barrier includes one or more ports for enabling oxygen to flow to the air cathode. 
     
     
         6 . An electrochemical cell system according to  claim 1 , further comprising a first terminal coupled to the fuel electrode of cell  1  and a second terminal, wherein the plurality of switches includes a switch switchable between coupling the oxidant electrode of cell N to the second terminal in the discharge mode, and coupling the charging electrode of cell N to the second terminal in the charge mode. 
     
     
         7 . An electrochemical cell system according to  claim 6 , wherein said plurality of switches are switchable to a bypass mode for each of said cells  1  to N, wherein:
 in said bypass mode for cell  1 , the first terminal is coupled to the fuel electrode of cell  2 ; 
 in said bypass mode for any cell X of cells  2  to N−1, the charging electrode, in the charge mode, or the oxidant electrode, in the discharge mode, of the previous cell (X−1) is coupled to the fuel electrode of the subsequent cell (X+1); and 
 in said bypass mode for cell N, the charging electrode, in the charge mode, or the oxidant electrode, in the discharge mode, of cell N−1 is coupled to the second terminal. 
 
     
     
         8 . An electrochemical cell system according to  claim 7 , wherein
 a static contact for the triple throw single pole switch for cell N is connected to the second terminal,   a first selective contact for the triple throw single pole switch for cell  1  is connected to at least the first terminal; and   a switch element for each triple throw single pole switch is switchable between (1) a bypass position coupling its static contact to its first selective contact, (2) a charging position coupling its static contact to its second selective contact, and (3) a discharging position coupling its static contact to its third selective contact, wherein said charging mode of said plurality of switches is established by said switch elements being in said charge positions thereof, said discharge mode is established by said switch elements being in said discharging positions thereof, and each cell may be bypassed by moving the switch element associated therewith to the bypass position in either the charge mode or the discharge mode of said plurality of switches.