	US 12,461,498 B2
	Advanced metal air electrochemical cell and method of fabrication
David L. Frank, Highland Beach, FL (US)
Assigned to Blue Horizons Innovations, LLC, Coconut Creek, FL (US)
Filed by Blue Horizons Innovations, LLC, Coconut Creek, FL (US)
Filed on Oct. 17, 2023, as Appl. No. 18/488,238.
Application 18/488,238 is a continuation of application No. 17/819,128, filed on Aug. 11, 2022, granted, now 11,687,052, issued on Jun. 27, 2023.
Claims priority of provisional application 63/430,102, filed on Dec. 5, 2022.
Prior Publication US 2024/0255913 A1, Aug. 1, 2024
Int. Cl. G05B 19/042 (2006.01); G08B 21/18 (2006.01); G10L 15/22 (2006.01); H01M 8/10 (2016.01); H02J 7/34 (2006.01)

CPC G05B 19/0428 (2013.01) [G08B 21/185 (2013.01); H01M 8/10 (2013.01); H02J 7/345 (2013.01); G05B 2219/24033 (2013.01); G10L 15/22 (2013.01); H02J 2207/50 (2020.01)]

16 Claims

1. An advanced rechargeable metal-air battery comprising:

one or more advanced air cathodes, an anode, a separator, and one or more electrolyte layers which are interposed between the advanced air cathode and the anode, and which conduct metal ions between the advanced air cathode and the anode,

wherein the advanced air cathode includes a gas diffusion layer, an electroconductive material, and an electrocatalyst layer; and

wherein the gas diffusion layer diffuses oxygen from ambient air providing oxygen to the electrocatalyst layer; and

an electrocatalyst layer being applied to the advanced air cathode of the advanced rechargeable metal-air battery:

wherein a base electrocatalyst material in the electrocatalyst layer is comprised of a modified perovskite material comprised of Calcium Copper Titanium Oxide (Ca_jCu_kTi_lO_m,) where j, k, l, and m, are within a range of 0 to 20; and

wherein the base electrocatalyst material is an internal barrier capacitor material having grain boundaries that provide electrocatalyst properties and first and second resistive materials bonded to the grain boundaries of the base electrocatalyst material to form modified grain boundaries of the base electrocatalyst material thereby forming a modified internal barrier capacitor material; and

wherein one or more additional oxide materials are bonded to the grain boundaries of the internal barrier capacitor material forming a grain boundary composition which includes nanoparticles of a first resistive material added to nanoparticles of the internal barrier capacitor material, increasing performance of the electrocatalyst layer; and

wherein the base electrocatalyst material is combined with active carbon and one or more ionomers to form the electrocatalyst layer, and

wherein the electrocatalyst layer interfaces with electrolyte of the one or more electrolyte layers of the advanced rechargeable metal-air battery and performs bifunctional processes of oxygen reduction reaction (ORR) forming hydroxyl ions which migrate into the electrolyte; and

wherein a reversible reaction takes place at the electrocatalyst layer when charging release of O₂molecules (OER); and

wherein the electrolyte is comprised of one or more selected from:

a liquid electrolyte,

a gel-polymer electrolyte,

a combination of gel-polymer on an interface of the advanced air cathode and solid polymer on an interface of the anode,

an advanced solid polymer combined with a metal-organic-framework,

an advanced solid polymer comprised of one or more polymers and conductive additives, or

a deep eutectic solvent, and

wherein the anode is comprised of one or more of: aluminum, germanium, calcium, iron, lithium, magnesium, potassium, sodium, tin, or zinc.