Fast charge apparatus for a battery

A fast charge system (20) including a secondary battery (22) having a capacity to store a predetermined amount of electrical energy, said fast charge system (20) comprising;

• a pair of electrodes (32, 46) including an anode layer (32) and a cathode layer (46) extending in parallel and spaced relationship to one another,
• a membrane (38) sandwiched between said anode layer (32) and said cathode layer (46),
• a first electrolyte (44) including first ions (24) and impregnating said membrane (38) to carry an excess ion migration through said membrane (38) in response to the application of a maximum charging power (PMAX) as a function of a first voltage (V1) between said anode layer (32) and said cathode layer (46) times a first current (I1) therebetween and applied over a first time interval (T1),
• a fast charge composite (60) including a separator (62) impregnated with a second electrolyte (64) including third ions (94) having a positive charge and including fourth ions (96) having a negative charge and disposed adjacent to and contacting one of said electrodes (32, 46) rendering it an adjacent electrode (32, 46) and the remaining one of said electrodes (32, 46) being rendered a remote electrode (32, 46) electrically isolated from said fast charge composite (60),
• said adjacent electrode (32, 46) being permeable to said third ions (94) and said fourth ions (96) for allowing said third ions (94) and said fourth ions (96) to penetrate within said adjacent electrode (32, 46),
• said fast charge composite (60) including a fast charge layer (30) disposed adjacent and parallel to said separator (62) with said separator (62) sandwiched between said adjacent electrode (32, 46) and said fast charge layer (30) to electrically insulate said fast charge layer (30) from said adjacent electrode (32, 46) and for exchanging said third ions (94) and said fourth ions (96) through said separator (62) with said adjacent electrode (32, 46),
• said fast charge composite (60) including a fast charge lead (68) of electrically conductive material electrically connected to said fast charge layer (30) for the application of a second electrical power (PFC) greater than said maximum charging power (PMAX) and a function of a second voltage (V2) between said fast charge lead (68) and said battery lead (34, 50) of said adjacent electrode (32, 46) times a second current (I2) therebetween and applied over a second time interval (T2) to cause said third ions (94) and said fourth ions (96) to migrate between said adjacent electrode (32, 46) and said fast charge layer (30) to change the electrochemical potential of said adjacent electrode (32, 46) to enable said secondary battery (22) to store said predetermined amount of electrical energy in less said second time interval (T2) than said first time interval (T1) when subjected at and below said maximum charging power (PMAX).

A fast charge system (20) including a secondary battery (22) having a capacity to store a predetermined amount of electrical energy, said fast charge system (20) comprising;

• a pair of electrodes (32, 46) including an anode layer (32) and a cathode layer (46) extending in parallel and spaced relationship to one another,
• said anode layer (32) consisting of 99.4 to 99.9 wt % of solid Aluminum of 99.95% purity and 0.1 to 0.6 wt % of Indium and having first rectangular borders defining a first length of 1.2 cm and a first width of 1.7 cm and a first thickness of 0.1 mm,
• a negative battery lead (34) of an electrically conductive material in electrical contact with said anode layer (32) for conducting electrical current with external circuitry,
• a cement (36) including particles (92) containing metal and disposed between said anode layer (32) and said negative battery lead (34) for attaching said anode layer (32) to said negative battery lead (34) and for conducting electrical current therebetween,
• said cathode layer (46) having second rectangular borders defining a second length of 1.4 cm and a second width of 1.9 cm and a second thickness of 0.1 mm,
• said cathode layer (46) including a carrier sheet (48) of cellulose and an electroactive layer (28) integrated with and upon said carrier sheet (48) facing said anode layer (32),
• a positive battery lead (50) containing thermally expanded graphite in electrical contact with said electroactive layer (28) of said cathode layer (46) for conducting electrical current with external circuitry,
• an adhesive (52) containing graphite disposed between said electroactive layer (28) and said positive battery lead (50) for attaching said electroactive layer (28) to said positive battery lead (50) and for conducting electrical current therebetween,
• a membrane (38) of cellulose having a third thickness (40) of 0.08 mm and defining a plurality of pores (42) and sandwiched between said anode layer (32) and said cathode layer (46) for providing electrical insulation and to define a first voltage (V1) therebetween,
• a first electrolyte (44) including first ions (24) containing Aluminum and having a positive charge and including second ions (26) containing Aluminum and having a negative charge and impregnating said pores (42) of said membrane (38) and carrying an excess ion migration through said membrane (38) in response to the application of a first current (I1) between said positive battery lead (50) and said negative battery lead (34) greater than a predetermined maximum current (IMAX) and to define a maximum charging power (PMAX) as said first voltage (V1) times said first current (I1) with one of said first voltage (V1) in excess of a predetermined maximum voltage (VMAX) and said first current (I1) in excess of said maximum current (IMAX) and applied over a first time interval (T1) to damage said secondary battery (22),
• said first electrolyte (44) consisting essentially of glycerol and said first ions (24) containing Aluminum including [Al(ClO4)2.{C3H5(OH)3}2]+ and said second ions (26) containing Aluminum including [Al(ClO4)4]− for migrating between and reacting with said anode layer (32) and said cathode layer (46) to charge and discharge said secondary battery (22),
• said electroactive layer (28) of said cathode layer (46) containing a host lattice (54) having a conjugated system with delocalized π electrons and defining voids (56) and a dopant (58) containing Aluminum Alcoholate and Aluminum Glycerate bonded with said conjugated system of said host lattice (54) and intercalated in said voids (56) to alter the electrochemical properties of said electroactive layer (28) of said cathode layer (46) to increase the rate of the reactions with said first ions (24) and said second ions (26) for charging and discharging said secondary battery (22),
• and characterized by,
• a fast charge composite (60) having third rectangular borders between said first and said second rectangular borders and including a separator (62) of cellulose for providing electrical insulation and impregnated with a second electrolyte (64) including third ions (94) containing Aluminum and having a positive charge and including fourth ions (96) containing Aluminum and having a negative charge and disposed parallel to and contacting one of said electrodes (32, 46) rendering it an adjacent electrode (32, 46) and the remaining one of said electrodes (32, 46) a remote electrode (32, 46) electrically isolated from said fast charge composite (60),
• said adjacent electrode (32, 46) being permeable to said third ions (94) and said fourth ions (96) for absorbing and reacting with said third ions (94) and said fourth ions (96) within said adjacent electrode (32, 46),
• said fast charge composite (60) including a fast charge layer (30) comprising foil (66) of thermally expanded graphite disposed adjacent and parallel to said separator (62) with said separator (62) sandwiched between said adjacent electrode (32, 46) and said fast charge layer (30) to electrically insulate said fast charge layer (30) from said adjacent electrode (32, 46),
• said fast charge composite (60) including a fast charge lead (68) of electrically conductive material electrically connected to said fast charge layer (30) for the application of a second electrical power (PFC) greater than said maximum charging power (PMAX) and a function of a second voltage (V2) between said fast charge lead (68) and said battery lead (34, 50) of said adjacent electrode (32, 46) times a second current (I2) therebetween and applied over a second time interval (T2) to cause said third ions (94) and said fourth ions (96) to migrate through said separator (62) between said adjacent electrode (32, 46) and said fast charge layer (30) to change the electrochemical potential of said adjacent electrode (32, 46) and to enable said secondary battery (22) to store said predetermined amount of electrical energy in less said second time interval (T2) than said first time interval (T1) when subjected at and below said maximum charging power (PMAX).

A method for constructing a fast charge composite (60) combined with secondary battery (22) having an anode layer (32) and a cathode layer (46), said method comprising;

• stacking a separator (62) of electrically insulating material upon and parallel to one of said anode layer (32) and said cathode layer (46) rendering it an adjacent electrode (32, 46),
• stacking a fast charge layer (30) upon and parallel to the separator (62) with the separator (62) disposed between said adjacent electrode (32, 46) and said fast charge layer (30),
• and characterized by,
• dissolving AlCl3 in ethanol to create a background solution (78),
• combining the background solution (78) with glycerol to produce a second electrolyte (64) including third ions (94) having a positive charge and including fourth ions (96) having a negative charge,
• wetting the separator (62) with the second electrolyte (64).

A method for constructing a fast charge composite (60) combined with a secondary battery (22) having an anode layer (32) and a cathode layer (46), said method comprising;

• stacking a separator (62) of electrically insulating material upon and parallel to one of said anode layer (32) and said cathode layer (46) rendering it an adjacent electrode (32, 46),
• stacking a fast charge layer (30) of thermally expanded graphite upon and parallel to the separator (62) with the separator (62) disposed between the adjacent electrode (32, 46) and the fast charge layer (30),
• attaching a fast charge lead (68) in electrical contact with the fast charge layer (30) with an adhesive (52) of graphite paint,
• and characterized by,
• dissolving AlCl3 powder in ethanol to saturation to create a background solution (78),
• combining 40 wt % of the background solution (78) with 60 wt % of glycerol to make a binary solvent (80),
• grating 1 cm3 of 99.4 to 99.9 wt % of Aluminum of 99.95% purity and 0.1 to 0.6 wt % of Indium to make filings (82) with an equivalent surface area of 20 to 30 cm2,
• immersing the filings (82) in 150 to 200 ml of the binary solvent (80) until the filings (82) have dissolved to produce a second electrolyte (64) including third ions (94) containing Aluminum and having a positive charge and including fourth ions (96) containing Aluminum and having a negative charge,
• wetting the separator (62) with the second electrolyte (64).