Advanced metal air electrochemical cell and method of fabrication

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 (CajCukTilOm,) 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 O2 molecules (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.