METAL-AIR BATTERY FOR A VEHICLE

Abstract

A metal-air battery for a vehicle may include an electrolyte and/or an electrode that is readily replaceable and/or drainable and/or fillable by an end user of the vehicle. The electrolyte may be replaced while the metal-air battery is installed on the vehicle, or while the metal-air battery is installed on a battery station, which may be separate from the vehicle. The battery may include a valve assembly configured to control the flow of electrolyte to and/or from the battery module and provided between a duct assembly and the battery module. A valve assembly may be provided on the battery module, the electrolyte module, and/or the duct assembly and configured to open upon connection of the battery module and close upon disconnection with the duct assembly. A pump may be associated with the battery module, electrolyte module and/or the duct assembly to move electrolyte therebetween.

Claims

1. A vehicle metal-air battery, comprising: a battery module comprising a first casing and an electrode assembly having a metal anode and an air cathode disposed within the first casing; an electrolyte module comprising a second casing configured to contain an electrolyte; a valve selectively fluidly connecting the battery module to the electrolyte module via a duct assembly; and an electrical connector configured to connect the battery module with another battery module or a vehicle system.

2. The vehicle metal-air battery of claim 1 further comprising a handle connected to at least one of the first casing and the second casing.

3. The vehicle metal-air battery of claim 1 further comprising a pump configured to pump the electrolyte between the battery module and the electrolyte module.

4. The vehicle metal-air battery of claim 3 wherein the pump is disposed within the duct assembly.

5. The vehicle metal-air battery of claim 1 wherein the electrolyte comprises water.

6. The vehicle metal-air battery of claim 1 wherein at least one of the battery module and the electrolyte module is configured to be installed on and/or removed from a vehicle by an end user of the vehicle without using tools.

7. The vehicle metal-air battery of claim 1 wherein the duct assembly is configured for permanent installation on a vehicle.

8. The vehicle metal-air battery of claim 1 wherein the duct assembly comprises: a battery module connector configured to receive the battery module; an electrolyte module connector configured to receive the electrolyte module; and a duct fluidly connected between the battery module connector and the electrolyte module connector.

9. The vehicle metal-air battery of claim 8 wherein at least one of the battery module connector and the electrolyte module connector is configured to receive a signal from a controller to selectively release either or both of the battery module and the electrolyte module from the duct assembly.

10. The vehicle metal-air battery of claim 1 wherein the valve is configured to open upon connection of the battery module to the duct assembly.

11. The vehicle metal-air battery of claim 1 wherein the valve is configured to open upon connection of the electrolyte module to the duct assembly.

12. The vehicle metal-air battery of claim 1 wherein the valve is connected to the battery module and is configured to close upon disconnection of the battery module from the duct assembly.

13. The vehicle metal-air battery of claim 1 wherein the valve is connected to the battery module, the metal-air battery further comprising a second valve connected to the electrolyte module, wherein the valve and the second valve are configured to open upon connection of the battery module and electrolyte module, respectively, to the duct assembly, and to close upon disconnection of the battery module and the electrolyte module, respectively, from the duct assembly.

14. A metal-air battery system comprising: a vehicle metal-air battery having a battery module containing a cathode and an anode, and an electrolyte module configured to selectively provide an electrolyte to the battery module, at least one of the battery and electrolyte modules being removable; and a metal-air battery station having an opening for receiving the at least one removable module and to replace the electrolyte contained therein.

15. The metal-air battery system of claim 14 wherein the at least one removable module comprises a handle configured for removing and carrying the module.

16. The metal-air battery system of claim 14 further comprising a duct assembly installed in a vehicle, the duct assembly comprising: a battery module connector configured to receive the battery module; an electrolyte module connector configured to receive the electrolyte module; and a duct fluidly connected between the battery module connector and the electrolyte module connector; and wherein the vehicle metal-air battery further comprises a first valve associated with the battery module that operates in response to installing or removing the battery module, and a second valve associated with the electrolyte module that operates in response to installing or removing the electrolyte module.

17. The metal-air battery system of claim 14 wherein the metal-air battery station is configured to replace used electrolyte from an electrolyte module placed in the opening with fresh electrolyte.

18. A metal-air battery system for a vehicle, comprising: a battery module having a casing with a metal cathode and an air anode; an electrolyte module having a casing configured to contain an electrolyte; and a valve configured to contain the electrolyte within at least one of the battery module and the electrolyte module when removed from the vehicle and to fluidly couple the battery module and the electrolyte module when installed in the vehicle.

19. The metal-air battery system of claim 18 further comprising a duct assembly mounted to the vehicle, the duct assembly comprising: a battery module connector configured to receive the battery module; an electrolyte module connector configured to receive the electrolyte module; a duct fluidly connecting the battery module connector and the electrolyte module connector; and a pump configured to pump the electrolyte through the duct.

20. The metal-air battery system of claim 19 further comprising a handle connected to at least one of the battery module and the electrolyte module configured for removing and carrying the at least one module.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 shows a battery module of a metal-air battery according to a representative embodiment;

[0033] FIG. 2 shows an electrolyte module of a metal-air battery according to a representative embodiment;

[0034] FIGS. 3A to 3C show various arrangements of a metal-air battery according to representative embodiments;

[0035] FIG. 4 shows a metal-air battery station according to a representative embodiment; and

[0036] FIGS. 5A and 5B show a metal-air battery system according to a representative embodiment.

DETAILED DESCRIPTION

[0037] As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely representative and may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments and variations whether or not explicitly described or illustrated.

[0038] The present disclosure provides a metal-air battery 101 (FIGS. 3A-3C) for a vehicle. The vehicle may be any type of vehicle which uses a battery to power one or more systems of the vehicle. In the below description, the metal-air battery 101 is a battery that is used to power a motor or electric machine of the vehicle, sometimes referred to as a motor-generator or traction motor. However, the metal-air battery 101 may be used to power any appropriate device.

[0039] Electric vehicles generally have a more limited driving range than gasoline or diesel powered vehicle, which may be a result of an electrode and/or an electrolyte of the battery becoming depleted. In the context of the present disclosure, the terms depleted electrolyte and depleted electrode are used to describe an electrolyte and an electrode respectively whose functional efficiency has dropped below a predetermined level. Once the electrolyte and/or the electrode has become depleted, the efficiency of the metal-air battery 101 may be such that at least one of the depleted electrode and the depleted electrolyte requires replacement. One problem associated with metal-air batteries, however, is that the electrolyte depletes at a faster rate than a metal anode of the metal-air battery 101. As a result, the electrolyte may need to be replaced at more frequent intervals than the metal anode. The present disclosure provides an improved metal-air battery 101 that can extend the driving range of the vehicle by allowing the electrolyte of the metal-air battery 101 to be readily replaced by an end user of the vehicle. In this manner, the entire metal-air battery 101 need not be replaced when the functional efficiency of the battery drops below the predetermined level.

[0040] In the context of the present disclosure, the term end user is understood to mean the consumer, for example a person who purchases goods for personal use, or in other words, a person who actually uses a particular product. For example, the end user of the vehicle may typically be the driver of the vehicle, and/or one or more passengers of the vehicle. It is understood, therefore, that the metal-air battery 101 according to the present disclosure is configured so that the driver and/or a passenger of the vehicle can replace the electrolyte of the metal-air battery 101 in a similar manner to refilling a fuel tank of a conventional gasoline-fueled or diesel-fueled vehicle.

[0041] FIGS. 1-3 show a battery module 103 and an electrolyte module 105 of the metal-air battery 101 respectively. The battery module 103 is configured to be installed on and/or removed from the vehicle by the end user. For example, the battery module 103 comprises a handle 107 that can be used to carry the battery module 103. The battery module 103 may be appropriately sized so that it can be carried and lifted by the end user of the vehicle. In one arrangement, the battery module 103 may have a mass in the range of 0.5 to 5 kilograms, for example when the battery module 103 is or is not filled with electrolyte.

[0042] The battery module 103 comprises a casing 109 that is configured to house the components of the metal-air battery 101. In the arrangement shown in FIG. 1, the casing 109 is configured to house one or more electrode assemblies 111 formed from at least one metal anode 113 and at least one air cathode 115. The casing is provided with an electrical connector 114, which is configured to connect electrically the battery module 103 with one or more other battery modules 103 and/or one or more vehicular systems.

[0043] The casing 109 is configured to seal an electrolyte 116 within the battery module 103, such that the electrolyte 116 fluidly connects the metal anode 113 to the air cathode 115. The electrolyte 116 may be water, or any other appropriate type of electrolyte. The casing 109 comprises a sealable opening 117 configured to allow the electrolyte 116 to flow between the interior and exterior of the casing 109 of the battery module 103. The battery module 103 comprises a valve assembly 119 configured to control the flow of electrolyte 116 across the opening 117 in the casing 109.

[0044] The casing 109 is provided with one or more ports configured to allow gas, for example air or oxygen, to flow between the exterior of the battery module 103 and the air cathode 115. In another arrangement, the air cathode 115 may form at least a portion of the exterior surface of the casing 109, so that the air cathode 115 is in direct contact with the environment external to the battery module 103.

[0045] In a similar manner to the battery module 103, the electrolyte module 105 is configured to be installed on and/or removed from the vehicle by the end user. In one arrangement, the electrolyte module 105 is configured to store the electrolyte 116, for example water. However, the electrolyte module 105 may be configured to store any appropriate type of electrolyte 116. The electrolyte module 105 comprises a casing 121, an opening 123 and a valve assembly 125 similar to those of the battery casing 109, so that the electrolyte 116 can be stored in the casing 121 and transferred across the opening 123 by way of operation of the valve assembly 125.

[0046] In the arrangement shown in FIGS. 1 and 2, the battery module 103 and the electrolyte module 105 are similarly shaped and sized. For example, at least one of the casing 109 and the valve assembly 119 of the battery module 103 may be of the same respective configuration as the casing 121 and the valve assembly 125 of the electrolyte module 105. However, in one or more alternative arrangements, the battery module 103 and electrolyte module 105 may be independently configured.

[0047] In one arrangement, at least one of the battery module 103 and the electrolyte module 105 is a replaceable component. For example, where the metal-air battery 101 is configured for use with the vehicle, either of the battery module 103 and the electrolyte module 105 may be uninstalled from the vehicle, and replaced by another battery module 103 or another electrolyte module 105. In this manner, it is possible to replace a depleted battery module 103 with a fresh battery module 103, and/or replace a depleted electrolyte module 105 with a fresh electrolyte module 105. In one arrangement, the battery module 103 may be a fixed battery module 103 that is not readily removable from the vehicle by the end user, and the electrolyte module 105 may be a replaceable module. Such an arrangement allows for the battery module 103 to be replaced during maintenance of the vehicle by a technician, and the electrolyte module 105 to be replaced during the day-to-day operation of the vehicle by the end user.

[0048] FIGS. 3A to 3C show various arrangements of the metal-air battery 101, which describe a possible operational mode of the metal-air battery 101. The metal-air battery 101 of FIGS. 3A to 3C includes a battery module 103, an electrolyte module 105 and a duct assembly 127. The duct assembly 127 is configured to fluidly connect the battery module 103 and the electrolyte module 105. Either end of the duct assembly 127 may comprise a connector configured to receive the battery module 103 or the electrolyte module 105. In the arrangement shown in FIGS. 3A to 3C, one end of the duct assembly 127 comprises a battery module connector 129 configured to receive the battery module 103, and the other end of the duct assembly 127 comprises an electrolyte module connector 131 configured to receive the electrolyte module 105. The connectors 129, 131 of the duct assembly 127 may each be configured to releasably secure the battery module 103 and the electrolyte module 105 to the duct assembly 127, for example by virtue of one or more fasteners and/or releasable snap fixings to facilitate installation and removal of at least one of the battery module 103 and the electrolyte module 105 by an end user without using tools. In one arrangement, the metal-air battery 101 may comprise a controller configured to control the connection between the duct assembly 127 and either or both of the battery module 103 and the electrolyte module 105. For example, the controller may be configured to control the release of the either or both of the battery module 103 and the electrolyte module 105 depending on the operational state, e.g. the functional efficiency, of the metal-air battery 101.

[0049] In the arrangement shown in FIGS. 3A to 3C, the battery module 103 does not comprise the valve assembly 119, as shown in the arrangement of FIG. 1. Instead, the battery module connector 129 of the duct assembly 127 comprises the valve assembly 119. It is understood, however, that the valve assembly 119 may be provided on the battery module 103 in addition to or alternatively from arrangements shown in FIGS. 3A to 3C. In contrast, the electrolyte module connector 131 does not comprise the valve assembly 125, the valve assembly 125 being provided on the electrolyte module 105 in this case.

[0050] A method of refilling the electrolyte of the battery module 103 will now be described with reference to FIGS. 3A to 3C and FIG. 4. The method may comprise the steps of draining a used electrolyte from the battery module 103, connecting fluidly a supply of new electrolyte 116 to the battery module 103, and filling the battery module 103 with the supply of new electrolyte 116.

[0051] With reference to FIGS. 3A to 3C, FIG. 3A shows a drained battery module 103 and a full electrolyte module 105, each of the modules 103, 105 being disconnected from the duct assembly 127. FIG. 3B shows the step of establishing a fluid connection between the battery module 103 and the electrolyte module 105 by virtue of the duct assembly 127. In FIG. 3B, the battery module 103 has been inserted into the battery module connector 129 of the duct assembly 127, which causes a first valve 128 to move from a closed position and an open position. In a similar manner, the electrolyte module 105 has been inserted into the electrolyte module connector 131 of the duct assembly 127, which causes a second valve 132 to move between a closed position and an open position. As a result of inserting both of the battery module 103 and the electrolyte module 105 into the respective connectors 129, 131 of the duct assembly 127, a fluidic connection is established between the battery module 103 and the electrolyte module 105. FIG. 3B shows the electrolyte 116 flowing from the electrolyte module 105 into the duct assembly 127.

[0052] FIG. 3C shows the transfer of the electrolyte 116 from the electrolyte module 105 into the battery module 103. In one arrangement, the duct assembly 127 may comprise a pump 133 configured to flow electrolyte 116 between the electrolyte module 105 and the battery module 103. Alternatively or additionally, the metal-air battery 101 may be configured to pressurize at least one of the battery module 103 and that the electrolyte module 105 to cause the electrolyte 116 to flow between the battery module 103 and the electrolyte module 105. In an alternative arrangement, the electrolyte 116 may simply be gravity fed between the electrolyte module 105 and the battery module 103.

[0053] The arrangements shown in FIGS. 3A to 3C, show the filling of electrolyte 116 into a pre-drained battery module 103. However, the method may comprise a step of draining a battery module 103 that is full of depleted electrolyte 116 into an empty electrolyte module 105. Once the battery module 103 has been drained of depleted electrolyte 116, and the electrolyte module 105 has been filled with the depleted electrolyte 116, the electrolyte module 105 may be removed from the electrolyte module connector 131 of the duct assembly 127 assembly, and replaced with another electrolyte module 105 filled with fresh electrolyte 116.

[0054] In another arrangement, the battery module 103 may be filled with depleted electrolyte 116 and the electrolyte module 105 may be filled with fresh electrolyte 166, when inserted into respective connectors 139, 131 of the duct assembly 127 assembly. In such an arrangement, the metal-air battery 101 may be configured to simultaneously transfer the depleted electrolyte 116 into the electrolyte module 105, and the fresh electrolyte 116 into the battery module 103. Such a transfer may be carried out using a single duct assembly 127 which allows for the transfer of depleted electrolyte 116 and fresh electrolyte 116 at the same time. Additionally or alternatively, the metal-air battery 101 may comprise another duct assembly 127 and/or one or more further valve assemblies 119, 125 configured to effect the above described simultaneous transfer of depleted electrolyte 116 and fresh electrolyte 116.

[0055] FIG. 4 shows a battery station 135 for use with the above mentioned metal-air battery 101. The battery station 135 comprises a housing 137 having one or more openings 139 configured to receive the battery module 103 and/or electrolyte module 105. In the arrangement shown in FIG. 4, each of the openings 139 has a similar configuration since the battery module 103 and the electrolyte module 105 are of similar shape and size. However, in another arrangement, the openings 139 may have any appropriate configuration. For example, the housing 137 may comprise a battery module opening configured to receive only the battery module 103, and an electrolyte module opening configured to receive only the electrolyte module 105. In this manner, the electrolyte module 105 may not be placed in an opening for the battery module 103, and the battery module 103 may not be placed in an opening for the electrolyte module 105.

[0056] The battery station 135 may be a refilling station that is configured to drain depleted electrolyte 116 from the electrolyte module 105 and refill the electrolyte module 105 with fresh electrolyte 116. For example, a driver of the vehicle may remove an electrolyte module 105 filled with depleted electrolyte 116 from the vehicle, deposit the electrolyte module 105 filled with depleted electrolyte into the battery station 135, and the battery station 135 may drain and refill the electrolyte module 105, so that the driver may reinstall the electrolyte module 105 on the vehicle. Additionally or alternatively, the battery station 135 may be configured to receive the electrolyte module 105 filled with depleted electrolyte, and dispense another electrolyte module 105 filled with fresh electrolyte.

[0057] In one arrangement, the battery station 135 may be connected to an external electrolyte reservoir 141. For example, the battery station 135 may be configured to drain depleted electrolyte 116 from the electrolyte module 105 and refill the electrolyte module 105 with fresh electrolyte 116 from the electrolyte reservoir 141. Additionally or alternatively, the battery station 135 may comprise an internal supply of electrolyte 116, which may be drained and/or refilled periodically during maintenance of the battery station 135.

[0058] In one arrangement, the battery station 135 may be configured to connect the electrolyte supply 141 to the metal-air battery 101 of the vehicle. For example, the battery station 135 may comprise a fluidic coupling, such as a hose, that is connectable directly to the battery module 103 and/or the electrolyte module 105 installed on the vehicle. In this manner, the electrolyte 116 can be drained and/or filled as required, without the need for removing either of the battery module 103 or the electrolyte module 105 from the vehicle. In one arrangement, the battery station 135 may be connectable to the battery module connector 129 and/or the electrolyte module connector 131 of the duct assembly 127, so that the battery module 103 can be drained and/or filled as required.

[0059] The battery station 135 may be configured to receive at least one depleted battery module 103. For example, where the battery module 103 has been drained and refilled a plurality of times with electrolyte 116, the metal anode of the battery module 103 may require replacement. In one arrangement, the present disclosure allows for the end user to remove a depleted battery module 103, for example which has been drained of electrolyte 116, and then deposit the depleted battery module 103 in the battery station 135. The end user may then take a fresh battery module 103 from the battery station 135 and reinstall it in the vehicle.

[0060] In one arrangement, the battery station 135 may be configured to remove a depleted metal anode from the battery module 103, and replace the depleted metal anode with a fresh metal anode. In this manner, the battery station 135 may be configured to recondition the battery module 103 in addition to or alternatively from the refilling of the electrolyte module 105.

[0061] In one arrangement, the battery station 135 may be configured to vend at least one of the electrolyte module 105 and the battery module 103. In this manner, the battery station 135 may serve as a refueling station for the vehicle.

[0062] FIGS. 5A and 5B show a metal-air battery system 143 comprising at least one metal-air battery 101, for example the metal-air battery 101 of the vehicle, and a plurality of the battery stations 135. FIG. 5A shows an arrangement where the battery modules 103 and electrolyte modules 105 are arranged in a trunk of the vehicle, and depicts the end user removing a depleted electrolyte module 105 from the vehicle, and replacing the depleted electrolyte module 105 with a fresh electrolyte module 105, which may be obtained from the battery station 135.

[0063] The battery station 135 may be placed in any appropriate location where it is convenient for the end user to replace the electrolyte module 105 and/or the battery module 103 of the vehicle. For example, the battery station 135 may be configured to be installed in a parking lot, a place of work and/or at the home of the end user.

[0064] It will be appreciated by those skilled in the art that although the claimed subject matter has been described by way of example with reference to one or more examples, it is not limited to the disclosed examples and that alternative examples could be constructed without departing from the scope of the disclosure as defined by the appended claims.

[0065] While representative embodiments are described above, it is not intended that these embodiments describe all possible forms of the claimed subject matter. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure and claimed subject matter. Additionally, the features of various implementing embodiments may be combined to form further embodiments that are not explicitly illustrated or described.