Metal-air battery system & methods

Abstract

Metal-air battery systems and methods configured for mechanical recharging / refueling via replacement of metal anode cartridge(s) are provided. For example, a method includes providing a metal-air battery having a first electrode module, a second electrode module, and a metal anode cartridge disposed between the first electrode module and the second electrode module. At least one of the first electrode module and the second electrode module is moved relative to each other to expose the metal anode cartridge in an open configuration. The metal anode cartridge is extracted from between the first electrode module and the second electrode module. A second metal anode cartridge is inserted between the first and second electrode modules. The first and second electrode modules are closed about the second metal anode cartridge to secure the second metal anode cartridge between the first and second electrode modules in a closed operational configuration.

Description

Metal-Air Battery System and MethodsCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of United States provisional application no. 63 / 687,085 entitled “Metal-Air Battery System & Methods” and filed August 22, 2024, United States provisional application no. 63 / 716,538 entitled “Metal-Air Battery System & Methods” and filed November 5, 2025, and United State provisional application no. 63 / 853,352 entitled “Metal- Air Battery System & Methods” and filed July 29, 2025, each application of which is hereby incorporated by reference as though fully set forth herein.GOVERNMENT LICENSE RIGHTS

[0002] This invention was made with government support under contract W911NF2220007 awarded by the Department of Defense. The government has certain rights in the invention.BACKGROUNDField

[0003] The instant disclosure relates to metal-air battery systems.Background

[0004] Metal-air batteries have the potential to supply the ever-growing energy needs of the world while being more cost-effective than Li-ion technology. They currently have the highest calculated theoretical specific energies among all electrochemical energy devices, and they can perform at high voltage and capacity efficiencies. A Metal-air battery includes a metal-based anode, with the most prominent of these being in the form of Zinc or Aluminum. Zinc-air batteries currently have the most marketability, commonly used within devices such as hearing aids systems, due to their reliable long-term stability compared to the other metal-air systems and their ability to be primary and secondary batteries.

[0005] During the discharging of these devices in an alkaline medium, oxidation of a metal species occurs at the anode electrode interface, and an oxygen reduction reaction (ORR) occurs at the air electrode interface. Anode reaction reactions occasionally co-occur in the presence of a third reactionary mechanism that occurs within the bulk electrolyte solution. During device charging, when applicable, reactions occur in the opposite direction leading to the reformation of the metaland the production of molecular oxygen. This process leads to an overall reaction that needs to be balanced depending on the metal species utilized in the device.

[0006] The affinity for these metals to lose multiple electrons, two by Zinc and three by Aluminum, leads to substantially high theoretical energy densities of approximately 1084 Wh / kg21for Zinc-air and 8100 Wh / kg20for Aluminum-air.

[0007] Compared to Li-ion batteries, Zinc-air and Aluminum-air batteries can produce four and thirty-two times the energy generated using market-leading systems. Unfortunately, these battery systems have not achieved even half of these theoretical values. This detriment is primarily due to the slow kinetics of the ORR at the cathode and the limitations at the anode, such as Zinc dendritic formation and the parasitic evolution of hydrogen gas that occurs during Aluminum implementation. To attempt and try to further increase Metal-air battery device viability by limiting the adverse effects, flow-type systems in the form of metal-air flow batteries (MABFs) are being introduced to limit product build-ups at the anode and cathode interfaces.

[0008] A conventional air electrode includes a gas diffusion layer (GDL), a microporous layer (MPL), an active catalyst layer (CL), and a metal current collector. Each layer of the air electrode structure contributes to the overall conductivity, mass transport properties, durability, porosity, and electrochemical activity of the electrode. These attributes impact the performance and lifetime of the electrochemical system.BRIEF SUMMARY

[0009] Metal-air battery systems and methods configured for mechanical recharging / refueling via replacement of metal anode cartridge(s) are provided.

[0010] In one embodiment, for example, a method includes providing a metal-air battery having a first electrode module, a second electrode module, and a metal anode cartridge disposed between the first electrode module and the second electrode module. At least one of the first electrode module and the second electrode module is moved relative to each other to expose the metal anode cartridge in an open configuration. The metal anode cartridge is extracted from between the first electrode module and the second electrode module. A second metal anode cartridge is inserted between the first and second electrode modules. The first and second electrodemodules are closed about the second metal anode cartridge to secure the second metal anode cartridge between the first and second electrode modules in a closed operational configuration.

[0011] In another embodiment, a manually rechargeable metal-air battery comprises: a first electrode module comprising a first housing partially enclosing a first electrode and a first electrolyte flow field; a second electrode module comprising a second housing partially enclosing a second electrode and a second electrolyte flow field; a metal anode cartridge disposed between the first and second electrolyte flow fields in a first closed operational configuration; and a connector coupling first housing to the second housing, the connector configured allow the first electrode module to move relative to the second electrode module to expose the metal anode cartridge for removal and replacement with a second metal anode cartridge, and to return the first electrode module and the second electrode module about the second metal anode cartridge in the first closed operational configuration.

[0012] In yet another embodiment, a compound metal-air battery system comprises: a plurality of electrode modules including a pair of end unit electrode modules; at least one replaceable metal anode cartridge disposed between adjacent electrode modules; and at least one connector configured to permit selective opening of the system to remove and replace one or more of the metal anode cartridges.

[0013] In another embodiment, a refueling kit for a mechanically rechargeable metal-air battery comprises: a plurality of metal anode cartridges; and a metal-air battery comprising: a plurality of electrode modules including a pair of end unit electrode modules; and at least one connector configured to permit selective opening of the system to remove and replace one or more of the metal anode cartridges.

[0014] The foregoing and other aspects, features, details, utilities, and advantages of the present invention will be apparent from reading the following description and claims, and from reviewing the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Fig. 1 is a schematic diagram showing an example embodiment of a single-sided air electrode module of a metal-air battery cell.

[0016] Fig. 2 is a schematic diagram showing another example embodiment of a single-sided membrane-less air electrode of a metal-air battery cell.

[0017] Fig. 3 is a schematic diagram showing an example embodiment of a double-sided air electrode module of a metal-air battery.

[0018] Fig. 4 is a schematic diagram showing another embodiment of a double-sided air electrode module of a metal-air battery.

[0019] Fig. 5 is a schematic diagram showing a single metal anode cartridge, expandable metal-air battery configured to be recharged / refueled by replacing the single metal anode cartridge with a replacement metal anode cartridge.

[0020] Fig. 6 is a schematic diagram showing a multiple-cartridge, expandable metal-air battery comprising a pair of back plate air electrode modules and a plurality (e.g., three) of metal anode cartridges disposed between the back plate air electrode modules.

[0021] Fig. 7 is a schematic diagram showing an alternative embodiment of an expandable metal air-battery in which a thickness of the back plate modules is increased to hold each of the plurality of metal anode cartridges within an outside of the body / housing of the modules.

[0022] Fig. 8 is a schematic diagram of a refuel operation for a multiple-cartridge expandable metal-air battery, such as shown in Figs. 6 and 7.

[0023] Fig. 9 is a schematic diagram of another embodiment of an expandable metal-air battery.

[0024] Fig. 10 is a schematic diagram showing another embodiment of a multiple cell single cartridge configuration in which metal anode cartridges are removed and replaced one at a time instead of all at once.

[0025] Fig. 11 is a schematic diagram showing example embodiments of connectors configured to allow modules of an expandable metal-air battery to move relative to one another and allow one or more cells of the battery to transition between a first closed operational configuration and a second open configuration.

[0026] Fig. 12 is a perspective view showing an embodiment of a cathode module.

[0027] Fig. 13 is an exploded view showing components of the cathode module of Fig. 12.

[0028] Fig. 14 is a diagram showing a male-type single-sided cathode back plate module.

[0029] Fig. 15 shows an example embodiment of a female-type single-sided cathode back plate module.

[0030] Fig. 16 shows an embodiment of a cathode middle plate.

[0031] Fig. 17 shows an example embodiment of connector bars for use in coupling adjacent modules of a stack.

[0032] Fig. 18 shows an example embodiment of a single cell configuration.

[0033] Fig. 19 shows an embodiment of a six-cell multi-cell stack configuration.

[0034] Fig. 20 shows additional views of the six-cell multi-cell stack configuration of Fig. 19.

[0035] Fig. 21 shows an example embodiment of an aluminum air battery comprising a modular structure.

[0036] Fig. 22 shows a battery module system comprising an array of aluminum air cells with N number of rows and M number of columns.

[0037] Figs. 23 and 24 show example electrolyte flow fields and that may be used within one or more air electrode modules to direct electrolyte across one or more surface of a metal anode cartridge.DETAILED DESCRIPTION

[0038] The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.

[0039] As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a” component caninclude two or more such components unless the context indicates otherwise. Also, the words “proximal” and “distal” are used to describe items or portions of items that are situated closer to and away from, respectively, a user or operator such as a surgeon. Thus, for example, the tip or free end of a device may be referred to as the distal end, whereas the generally opposing end or handle may be referred to as the proximal end.

[0040] All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader’s understanding of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other.

[0041] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0042] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0043] The term “substantially” as used herein may be applied to modify any quantitative representation which could permissibly vary without resulting in a change in the basic function to which it is related.

[0044] A compound metal-air battery system comprises a plurality of air electrode module components arranged with one or more metal anode cartridge components to provide one or more metal-air battery cells of the battery system.

[0045] Figs. 1 and 2, for example are schematic diagrams showing example single-sided back plate or end unit air electrode modules of a compound metal-air battery system comprising a plurality of individual metal-air battery cells of the system. Figs. 3 and 4 depict double-sided air electrode “middle plate” modules that may be combined with at least two single-sided back plate or end unit air electrode modules to provide a compound metal-air battery system.

[0046] Examples of compound metal-air battery systems comprising at least two single-sided back plate / end unit air electrode modules, one or more metal anode cartridge, and possibly one or more double-sided middle plate air electrode modules as constituent parts or building blocks to provide the compound metal-air battery system comprising a plurality of metal-air battery cells are shown in Figs. 5-10.

[0047] The compound metal-air batteries contemplated herein are applicable to any metal-air battery technology capable of recharge or refueling by replacement metal anode cartridges. Nonlimiting examples include aluminum, zinc, magnesium, or alloys thereof. Batteries with aqueous electrolytes can be used as safer handling alternatives, but non-aqueous electrolytes are also contemplated, especially where the replacement of the anode cartridges can be performed in an automated manner, such as via a robotic system.

[0048] Fig. l is a schematic diagram showing an example embodiment of a single-sided air electrode 10 of a metal-air battery cell. In this embodiment, the electrode 10 is part of a “back plate” or end unit module of the metal-air battery cell and provides structure of an air electrode of the metal-air battery cell. In this embodiment, the electrode is disposed at least in part within an outer housing 12 of the module with an open side configured to interact with a metal anode (negative electrode) of the metal-air battery. The housing serves to surround and protect air electrode components of the module and to allow the module to interact with a metal anode to form at least a portion of the metal air battery.

[0049] A bipolar plate / current collector 14 is disposed at a first end of the cell within the housing of the module. The bipolar plate / current collector 14 and provides an electrical connectionto the cathode of the metal-air battery and serves to conduct electrons away from the metal anode to an external circuit.

[0050] A gas diffusion layer (GDL) 16 is disposed adjacent to the bipolar plate / current collector 14. The GDL 16 has an effect on air electrode performance and mass transfer capabilities. The structure can depend on the nature of the system that the air electrodes are being implemented. For instance, when using a static system with no liquid electrolyte flow, a thinner GDL that has undergone hydrophilic treatments may be more beneficial in attempting to facilitate the movement of available water molecules to a catalyst layer 18 (CL) interface disposed adjacent to the gas diffusion layer (GDL) 16. Typically, systems without liquid flow rely on humidification for the incorporation of water vapor into the pores of the air electrode. However, when using a device that has multiple flow streams, including gas and electrolytic species, a thick GDL that has higher levels of hydrophobicity may be more viable in maximizing limiting current density values and managing the multiphase environment. Effective water management is used for achieving the power outputs at a range of voltage values because if there is not enough water within the MEA, ionic conductivity in the membrane can be lost. While an overabundance of these molecules leads to the phenomenon known as electrode flooding. The occurrence of flooding leads to the blocking of electrochemical active sites and inhibits the diffusion of gaseous reactant species to the CL via pore obstruction.

[0051] There currently are two main types of GDL used within EESDs, carbon felt and carbon paper. Using carbon felt rather than carbon paper as the GDL in the preparation of air electrodes increases the surface area and enhances the porosity which is substantial in high flow rate systems. The use of carbon papers occasionally leads to increased cathodic performance because the electrolyte and oxygen species can reach the CL surface faster due to their thicknesses being only a few hundred micrometers or less. The choice of the gas diffusion layer is substantial to performance because if the pores within the structure become blocked or impaired by electrolytic species or water, oxygen cannot reach the catalyst surface leading to the sluggish reaction kinetics that are seen for this half-cell reaction.

[0052] A membrane / separator 20 is disposed in this embodiment between the catalyst layer 18 and an electrolyte flow field 22. The electrolyte flow field 22 is configured to be placed in communication with a metal anode cartridge when the module is assembled to form the metal-air battery, such as shown in Fig. 5.

[0053] Fig. 2 is a schematic diagram showing another example embodiment of a single-sided membrane-less air electrode of a metal-air battery cell. Similar to Fig. 1, the electrode is part of a “back plate” or end unit module 30 of the metal-air battery cell and provides structure of an air electrode of the metal-air battery cell. In this embodiment, the electrode is disposed at least in part within an outer housing 32 of the module with an open side configured to interact with a metal anode (negative electrode) of the metal-air battery. The housing 32 serves to surround and protect air electrode components of the module and to allow the module to interact with the metal anode to form at least a portion of the metal air battery.

[0054] The module 30 of the metal-air electrode, in this embodiment, comprises a membraneless air electrode module 30.

[0055] A bipolar plate / current collector 34 is disposed at a first end of the cell within the housing of the module. The bipolar plate / current collector 34 provides an electrical connection to the cathode of the metal-air battery and serves to conduct electrons away from the metal anode to an external circuit.

[0056] A gas diffusion layer (GDL) 36 is disposed adjacent to the bipolar plate / current collector 34. A catalyst layer 38 is disposed adjacent to the gas diffusion layer on the opposite side of the gas diffusion layer from the bipolar plate / current collector 34.

[0057] An electrolyte flow field 42 is disposed adjacent to the catalyst layer 38. The electrolyte flow field 42 is configured to be in communication with a metal anode cartridge when the module is assembled to form the metal-air battery, such as shown in Fig. 5.

[0058] Figs. 1 and 2 depict an air electrode comprising a membrane layer and a membrane-less air electrode construction, respectively. Depending on the battery and application, a membrane may be easier to handle, such as with less free-flowing liquid. It also separates anode and cathode compartments to limit contamination of cathode with anode products and vice versa. A membrane can also potentially control the transport of ions within the cell to allow mainly transport of ions that participate in a cell reaction and limit gas crossover from an oxygen side to a metal (e.g., Al) side.

[0059] Methods of operating a metal-air battery include operations and / or processes that include flow of an electrolyte to a metal anode (e.g., aluminum anode) surface, metal (e g., aluminum) oxidation and oxygen reduction, corrosion of the metal anode material, plating of corrosion inhibitor(stannate) onto the metal anode material, hydrogen evolution caused by directmetal anode material reaction with water, ion transport through electrode and electrolyte (membrane and / or liquid), oxygen or air transport through a porous electrode including GDL and catalyst layers.

[0060] Fig. 3 is a schematic diagram showing an example embodiment of a double-sided air electrode module of a metal-air battery. In this embodiment, an air electrode is part of a “middle plate” module 50 of the metal-air battery cell that comprises a double-sided air electrode module. The double-sided air electrode module of the middle plate module includes components of two opposing air electrodes arranged on opposite sides of the module. Each of the opposing air electrodes are configured to couple with a respective metal anode cartridge to form a distinct metalair battery cell.

[0061] The two sides are separated by a wall 64, that, in some embodiments for example, can be integrated into the module hardware. In the embodiment shown in Fig. 3, for example, the wall 64 is a portion of an outer housing 52 of the module with a dual open sides 66 configured to interact with a pair of metal anode cartridges (negative electrodes) of the metal-air battery. The housing serves to surround and protect air electrode components of each air electrode of the dual module and to allow each side of the module to interact with opposing metal anodes to form at least a portion of the metal air battery. In this embodiment, the wall of the outer housing extends between a pair of air electrode structures and electrically isolates the air electrode structures from each other.

[0062] A metal-air battery may include any number of “middle plate” modules 50 disposed between a pair of “back plate” or end unit modules with metal anode cartridges (see, e.g., Figs. 9 and 10) disposed between the modules to form a plurality of individual metal-air battery cells of a compound metal-air battery system.

[0063] An electrolyte flow field 62 is disposed on an outer region of each side of the middle plate module 50 and is configured to be in communication with a metal anode cartridge when the air electrode module is assembled with the metal anode cartridge to provide a metal -air battery cell, such as shown in Figs. 9 and 10.

[0064] Each air electrode module 50 comprises a bipolar plate / current collector 54 disposed at a first end of the air electrode module adjacent to the wall 64 separating the dual air electrode modules from each other. The bipolar plate / current collector 54 of each air electrode moduleprovides an electrical connection to the cathode of the metal -air battery and serves to conduct electrons away from the metal anode to an external circuit.

[0065] A pair of gas diffusion layers (GDLs) 56 are disposed adjacent to the bipolar plate / current collector 54. A pair of catalyst layers 58 are disposed adjacent to the gas diffusion layer on the opposite side of the gas diffusion layer from the bipolar plate / current collectors of each air electrode module 50.

[0066] A pair of membranes / separators 60 are disposed external to and adjacent to the catalyst layers of the air electrode cells on each side of the middle plate module.

[0067] The electrolyte flow field 62 of each air electrode is disposed external to and adjacent to the electrode’s respective membrane / separator layer 60. Each of the electrolyte flow fields 62 is configured to be in communication with a metal anode cartridge when the module is assembled to form the metal -air battery, such as shown in Figs. 9 and 10.

[0068] The embodiments shown in Figs. 1 and 3 include components / building blocks of a compound metal air-battery system that are used with one or more metal anode cartridge to provide a plurality of metal-air battery cells. In one embodiment, for example, a metal-air battery cell of a compound system comprises at least two air electrode modules, such as a pair of coupled back plate or end unit modules, and back plate or end unit coupled to one side of a middle plate module, or opposing sides of two middle plate modules. The metal-air battery cell also comprises the following layers: a first bipolar plate / current collector, a first gas diffusion layer, a first catalyst layer, a first membrane / separator layer, a pair of electrolyte flow fields from a first module and a second module that are configured to receive and house an electrolyte for the metal-air battery cell, a second membrane / separator layer, a second catalyst layer, a second gas diffusion layer, and a second bipolar plate / current collector. In this example, the “first” components correspond to a first module, and the “second” components correspond to a second module disposed adjacent to the first module. A metal anode cartridge is disposed between the first and second electrolyte flow fields to complete the cell(s).

[0069] Fig. 4 is a schematic diagram showing another embodiment of a double-sided air electrode module 70 of a metal-air battery. In this embodiment, the electrode module 70 is a “middle plate” module 70 of the metal-air battery cell that comprises a double-sided air electrodemodule, similar to the embodiment shown in Fig. 3, but without including a membrane / separator layer.

[0070] The double-sided air electrode module of the middle plate module includes components of two opposing air electrodes arranged on opposite sides of the module. Each of the opposing air electrodes are configured to couple with a respective metal anode cartridge to form a distinct metalair battery cell.

[0071] The two sides are separated by a wall 84, that, in some embodiments for example, can be integrated into the module hardware. In the embodiment shown in Fig. 4, for example, the wall 84 is a portion of an outer housing 72 of the module with a dual open sides 86 configured to interact with a pair of metal anode cartridges (negative electrodes) of the metal-air battery. The housing serves to surround and protect air electrode components of each air electrode of the dual module and to allow each side of the module to interact with opposing metal anodes to form at least a portion of the metal air battery. In this embodiment, the wall of the outer housing extends between a pair of air electrode structures and electrically isolates the air electrode structures from each other.

[0072] The metal-air battery may include any number of “middle plate” modules disposed between a pair of “back plate” or end unit modules. The module 70 of the metal -air battery cell, in this embodiment, does not comprise a membrane.

[0073] An electrolyte flow field 82 is disposed on an outer region of each side of the middle plate module and is configured to be in communication with a metal anode cartridge when the air electrode module is assembled with the metal anode cartridge to provide a metal -air battery cell, such as shown in Figs. 9 and 10.

[0074] Each air electrode module 70 comprises a bipolar plate / current collector 74 disposed at a first end of the air electrode module adjacent to the wall 84 separating the dual air electrode modules from each other. The bipolar plate / current collector 74 of each air electrode module provides an electrical connection to the cathode of the metal -air battery and serves to conduct electrons away from the metal anode to an external circuit.

[0075] A pair of gas diffusion layers (GDLs) 76 are disposed adjacent to the bipolar plate / current collector 74 A pair of catalyst layers 78 are disposed adjacent to the gas diffusion layer on the opposite side of the gas diffusion layer from the bipolar plate / current collectors of each air electrode cell 70.

[0076] The electrolyte flow field 82 of each air electrode is disposed external to and adjacent to the electrode’s respective catalyst layer 78. Each of the electrolyte flow fields 82 is configured to be in communication with a metal anode cartridge when the module is assembled to form the metal-air battery, such as shown in Figs. 9 and 10.

[0077] The embodiments shown in Figs. 2 and 4 include components / building blocks of a membrane-less compound metal air-battery system that are used with one or more metal anode cartridge to provide a plurality of metal-air battery cells. In one embodiment, for example, a metalair battery cell of a compound system comprises two modules, such as a pair of coupled back plate or end unit modules, and back plate or end unit coupled to one side of a middle plate module, or opposing sides of two middle plate modules. The membrane-less metal-air battery cell also comprises the following layers: a first bipolar plate / current collector, a first gas diffusion layer, a first catalyst layer, a pair of electrolyte flow fields from a first module and a second module that are configured to receive and house an electrolyte for the metal-air battery cell, a second catalyst layer, a second gas diffusion layer, and a second bipolar plate / current collector. In this example, the “first” components correspond to a first module, and the “second” components correspond to a second module disposed adjacent to the first module. A metal anode cartridge is disposed between the first and second electrolyte flow fields to complete the cell(s).

[0078] Fig. 5 is a schematic diagram showing a single metal anode cartridge, expandable metal-air battery 100 configured to be recharged / refueled by replacing the single metal anode cartridge with a replacement metal anode cartridge. The expandable metal-air battery 100 is configured to be opened (e.g., expanded) from a first closed operational configuration 102 to a second open non-operational configuration 104, recharged by removal and replacement of the single metal anode cartridge 106, and closed (e.g., collapsed) and returned to use with the new replacement anode cartridge 108.

[0079] In this embodiment, the expandable metal-air battery is shown in the first closed operational configuration 102 in which a pair of back plate or end unit modules, such as shown in Figs. 1 and 2, are disposed on either side of a single metal anode cartridge 106 (e.g., the cartridge is sandwiched between the pair of modules) such that the either side of the single metal anode cartridge is in communication with the electrolyte flow field of each module.

[0080] In the example shown in Fig. 5, the modules of the expandable metal-air battery are coupled by a pair of pivotable connectors 108 coupled to housings 110 of each of the back plate end unit modules in an X-configuration so that as the expandable metal-air battery is transitioned between the closed and open configuration, the connectors pivot with respect to each other allowing the modules to move relative to each other.

[0081] In the first closed operational configuration, the back plate or end unit modules are disposed directly adjacent to the metal anode cartridge so that the expandable metal-air battery is functional.

[0082] In various implementations, the metal anode cartridge may be removed without removing electrolyte or after removing (e.g., draining the electrolyte) from the cell. In one example, the cell may comprise a manifold that contains an electrolyte. A port can be configured to allow the electrolyte to drain into a manifold compartment as a cartridge is lifted or otherwise removed for replacement. A new cartridge can be configured to wick or otherwise cause the electrolyte to be released from the manifold compartment when it is placed into the cell (e.g., connected to the manifold).

[0083] When the expandable metal-air battery is to be opened (e.g., to be recharged by replacement of the metal anode cartridge), the back plate modules are moved relative to each other (e.g., each module is moved away from the other), such as shown by arrows 112, the metal anode cartridge is released from the back plate modules and exposed such that the metal anode cartridge can be removed from the expandable metal-air battery as shown by arrow 114. The resulting non- operational configuration 104 is shown with the back plate modules separated from each other in the second open configuration without a metal anode cartridge in place.

[0084] A replacement metal anode cartridge is placed between the pair of back plate modules as shown by arrow 116 to refuel the metal-air battery. The back plate modules are then closed about the replacement metal anode cartridge to return to the first closed operational configuration, and the metal-air battery can be returned to service. In this or any other embodiment, a spent or replacement cartridge may be removed or added manually (e.g., by hand) and / or automatically (e.g., by robotics, or other automated functionalities such as using hardware or firmware). Similarly, the expandable metal-air battery may be opened and / or closed manually (e.g., by hand) and / or automatically (e.g., by robotics, or other automated functionalities such as using hardware or firmware).

[0085] Fig. 6 is a schematic diagram showing a multiple-cartridge, expandable metal-air battery 120 comprising a pair of back plate air electrode modules and a plurality (e.g., three) of metal anode cartridges disposed between the back plate air electrode modules. The expandable metal-air battery 120 is configured to be opened (e.g., expanded) from a first closed operational configuration to a second open non-operational configuration, recharged by removal and replacement of one or more of the multiple metal anode cartridges 122, and closed (e.g., collapsed) and returned to use with the new replacement anode cartridges.

[0086] Fig. 7 is a schematic diagram showing an alternative embodiment of an expandable metal air-battery 130 in which a thickness of the back plate modules is increased to hold each of the plurality of metal anode cartridges within an outside of the body / housing of the modules. In this embodiment, the leakage of electrolyte and / or gas media can be mitigated.

[0087] Fig. 8 is a schematic diagram of a refuel operation for a multiple-cartridge expandable metal-air battery, such as shown in Figs. 6 and 7. In this embodiment, the expandable metal-air battery is shown in the first closed operational configuration 140 in which a pair of back plate or end unit modules, such as shown in Figs. 1 and 2, are disposed on either side of a plurality of metal anode cartridges 142 (e.g., the cartridges are sandwiched between the pair of modules) such that the either side of the outer metal anode cartridges are in communication with the electrolyte flow field of each back plate module.

[0088] In the example shown in Fig. 8, the modules of the expandable metal-air battery are coupled by a pair of pivotable connectors 144 coupled to housings 146 of each of the back plate end unit air electrode modules in an X-configuration so that as the expandable metal-air battery is transitioned between the closed operational configuration 148 and the open configuration 150, the connectors pivot with respect to each other allowing the modules 152, 154 to move relative to each other.

[0089] In the first closed operational configuration, the back plate or end unit modules are disposed directly adjacent to the plurality of metal anode cartridges so that the expandable metal-air battery is functional and the plurality of metal anode cartridges are secured within the pair of back plate modules.

[0090] When the expandable metal-air battery is to be opened (e.g., to be recharged by replacement of one or more of the plurality of metal anode cartridges), the back plate modules aremoved away from each other, such as shown by arrows 156, and the metal anode cartridges are released from the back plate modules and exposed such that the metal anode cartridge can be removed from the expandable metal -air battery. The resulting non-operational configuration 150 comprises the back plate modules separated from each other in the second open configuration without contacting the metal anode cartridges.

[0091] One or more of the replacement metal anode cartridges are placed between the pair of back plate modules to refuel the metal-air battery. The back plate modules are then closed about the replacement metal anode cartridge(s) to return to the first closed operational configuration 148, and the metal-air battery can be returned to service.

[0092] Fig. 9 is a schematic diagram of another embodiment of an expandable metal-air battery 160. In this embodiment, the metal air-battery comprises a pair of back plate / end unit modules 162 surrounding a plurality of middle plate modules 164 (see e.g., Figs. 3 and 4). In this example, the battery system 160 comprises two back plate end unit modules 162 disposed at the terminal ends of the battery system 160 and three middle plate air electrode modules 164 disposed in series between the terminal pair of back plate end unit modules. A plurality of metal anode cartridges is disposed between each of the air electrode modules to provide a plurality of metal-air battery cells.

[0093] A plurality of connectors is provided coupling each of the adjacent back plate modules 162 and middle plate modules 164. As shown in Figs. 5 and 8, the connectors comprise pairs of pivotable connectors 166 coupled to housings of each of the back plate end unit modules in an X- configuration so that as the expandable metal-air battery is transitioned between the closed operational configuration 168 and the open configuration 170, the connectors pivot with respect to each other allowing the modules 162, 164 to move relative to each other.

[0094] In this embodiment, a single metal anode cartridge is disposed between each of the modules such that each side of each cartridge is in communication with the electrolyte flow field of each module.

[0095] The multiple-cell-single cartridge configuration can provide N number of metal anode cartridges and N+l or n number of air electrode module plates. The end modules 162 comprise back plate / end unit, single-sided module architectures, such as shown in Figs. 1 and 2. The middle plate modules 164 comprise double-sided architectures, such as shown in Figs. 3 and 4.

[0096] The expandable metal-air battery is opened, such as by expanding the back plate modules 162 and middle modules 164 away from each other to expose each of the metal anode cartridges. Any number of the exposed metal anode cartridges are removed as shown by arrows and replaced to refuel / recharge the metal-air battery. In one embodiment, for example, the plurality of metal anode cartridges may be removed and replaced all at one time to facilitate the refuel / recharge operation of each cell of the battery system.

[0097] The stack is closed returning the metal-air battery to the first closed operational configuration.

[0098] Fig. 10 is a schematic diagram showing another embodiment of a multiple cell single cartridge configuration of a metal-air battery system 180 in which metal anode cartridges are removed and replaced one at a time instead of all at once. In this example, one of the metal anode cartridges of the battery is exposed by moving one of the back plate or middle plate modules relative to another adjacent module without exposing additional metal anode cartridges of the battery.

[0099] As shown in Fig. 10, an outer cell 182 is opened exposing a first metal anode cartridge 184 for removal at a first operation. The first metal anode cartridge 184 is removed as shown at 186, and a replacement second metal anode cartridge 188 is provided in the opening 190. The outer cell is closed and returned to a closed operational configuration. In this manner, the first cartridge can be replaced without affecting the operation of the remaining cartridges.

[0100] In another operation, a cell in a central region of the battery is opened (e.g., in a subsequent operation after the first cartridge was replaced in the outer cell and the battery returned to operation), and a third metal anode cartridge 192 is removed from the cell and a replacement fourth metal anode cartridge is provided in the open cell 194 as shown at arrow 196. The surrounding modules of the cell are closed and the cell returned to a closed operational configuration.

[0101] Although the cells of Fig. 10 show single-cartridge configurations, multiple cartridge configurations for one or more of the cells may also be used, such as shown in Figs. 6 and 7.

[0102] Fig. 11 is a schematic diagram showing example embodiments of connectors configured to allow modules of an expandable metal-air battery to move relative to one another and allow one or more cells of the battery to transition between a first closed operational configuration and asecond open configuration. In this example, a pair of connectors 202 configured in an X configuration about a pivot point 204 is shown. In another embodiment, a pair of substantially parallel connectors 206 are provided linking a pair of adjacent modules of the battery.

[0103] The connectors shown in Fig. 11 are merely examples of possible connectors. One or more connectors may include at least one lock, snap, clip, pin, bolt, nut, and / or quick-release connector configured to secure the first and second electrode modules in the closed operational configuration. Further, any sliding or moving mechanisms can be used (e.g., integrated into the module architecture) or used for the process of a mechanical recharge process. For example, the connector may comprise a first locking / release mechanism, such as a at least one lock, snap, clip, pin, bolt, nut, and / or quick-release connector) configured to hold the modules in a first closed operational configuration. A second connector may be configured to allow at least one of the modules to move relative to the other, such as rails, bars, slides, pins, straps, wires, or the like. The second connector may also be configured to restrain at least one of the modules from moving past a predetermined limit location / di stance. For example, a first clip connector may secure the first and second modules with respect to each other. Unclipping the first connector may allow one or both of the modules to move relative to the other up to a limit (e.g., length) of a second connector such as a rail, bar, pin, strap, wire, etc. Further, connectors can be configured to both lock the modules in a closed operational configuration and allow / control the modules to be spaced relative to each other in a second open configuration. For example, a connector that provides an initial resistance to movement but then allows at least one of the modules to move relative to the other may be used.

[0104] In some embodiments, one or more of the modules may remain fixed while one or more other modules may be movable. In this manner, a first module is fixed, while a second module is movable relative to the first module to allow a spacing for removal of a metal anode cartridge to be removed and / or a replacement (or additional) metal anode cartridge to be inserted into the spacing. Further, a spent first cartridge of a plurality of cartridges may be removed from the spacing without replacement of the removed cartridge if desired.

[0105] Any manner of securing the modules and cartridge(s) in a closed operational configuration and allowing and / or controlling movement of at least one of the modules relative to the other is contemplated.

[0106] Fig. 12 is a perspective view showing an embodiment of a cathode module 210. Fig. 13 is an exploded view showing components of the cathode module 210 of Fig. 12. In this embodiment, the cathode module 210 comprises an air electrode, a bipolar plate / current collector, electrolyte flow field, and a membrane. The module 210 comprises a main body 212 of the cathode module and a face / holder 214 of the main components integrated into the cathode module 210. Fig. 13 shows a male-type of cathode module 216, and a female-type of a cathode module 218, which ultimately fit together during system operation. A differentiation is provided by a connection on the male-type cathode module 216, which facilitates the joint connectivity of the two respective plates.

[0107] In some embodiments, the cathode module comprises a double-sided module in which an air electrode and other components can be built into both sides of the module. In this case, especially during multiple cell assemblies (see, e.g., Figs. 9 and 10), the module can have one male side and one female side for interdigitation of additional modules in a stackable manner.

[0108] The cathode modules have inlet and outlet locations for the introduction of oxygen or air gas via an integrated manifold system. Additionally, there are entry and exit ports for the circulation of electrolytes.

[0109] Each part of the modules can be connected via one or more connectors (e.g., screws) from the top face to the main body.

[0110] Fig. 14 is a diagram showing a male-type single-sided cathode back plate module . In this embodiment, a cathode back plate module maintains a plurality of integral components for the operation of the cathode half cells. These modules include a main module hardware (1-11), a bipolar plate / current collector (12-14), an air electrode or air cathode (15), a membrane / separator in some embodiments, and an electrolyte flow field.

[0111] The module includes a main body 1, and a bracket 2 configured to support a metal anode cartridge during a mechanical refuel process. An oxygen or air gas manifold is configured for introduction of air electrode reactant molecules into the module. An additional manifold 3 may be disposed on the opposite side of the module for the outlet of oxygen or air gas (lower left side). The flowrate of oxygen or air can be dependent on the amount of this reactant needed for catalysis at the air electrode to reach the targeted system level power and energy.

[0112] An oxygen or air gas inlet 4 is provided. An outlet is provided on the opposite side of the module (lower left side).

[0113] An electrolyte manifold 5 is configured for the circulation of electrolyte within the modules. An additional electrolyte manifold is provided on the opposite side of the module for the outlet of electrolyte from the module (lower right side). The flowrate of electrolyte can be dependent on the amount needed for proper cell operation.

[0114] An electrolyte inlet 6 is configured to receive electrolyte. An outlet can be provided (e.g., on the opposite side of the module (lower right side)).

[0115] A bracket 7 is configured for a mechanical process. In one embodiment, for example, four of these brackets are provided, two on each side of the backplate module (top and bottom), for integration into the designed structure.

[0116] A hole 8 is configured for integration of the connectors that help facilitate the extension and retracting of the aluminum-air stack.

[0117] A hole 9 is configured for connection pegs or screws 10 that facilitate the attachment of the front 11 and back 1 bodies of the module.

[0118] A peg or screw 10 is configured for connection of the front 11 and back 1 bodies of the module.

[0119] A front body or face 11 is configured to help contain the components of the back plate module.

[0120] A bipolar plate / current collector 12 is provided.

[0121] An electrolyte flow field 13 is configured to direct electrolyte to the anode and / or cathode. In this embodiment, for example, the electrolyte flow field 13 provides a serpentine flow pattern, although any other electrolyte flow field may be used.

[0122] An oxygen or air gas inlet 14 is configured to provide an inlet into the bipolar plate / current collector. An outlet for oxygen or air gas can be provided on the opposite side of the plate.

[0123] Fig. 15 shows an example embodiment of a female-type single-sided cathode back plate module. In this embodiment, the design has the same components as Fig. 14 of the male-type cathode back plate module, except without a bracket for the aluminum cartridge to sit on in this female version of the cathode back plate module. Additionally, the oxygen / electrolyte manifolds, inlets, and outlets are on opposite sides of the module compared to the Male version of the module.This configuration allows for the inlets and outlets of the components to align during stack configuration construction.

[0124] Fig. 16 shows an embodiment of a cathode middle plate. In this embodiment the cathode middle plate has a main body like the single-sided modules, but it is double-sided for integration of major components on both sides of the module. In this embodiment, a male and a female side of the module are provided like the single-sided male and female back plate modules. The middle plate module contains two of each component (bipolar plate / current collector, membrane / separator, air electrode, etc.) arranged on opposite sides on the module. These two sides are separated by a wall that is integrated into the module hardware.

[0125] In this embodiment, the male side 220 of the cathode middle plate module is shown on the left side, and the female side 222 of cathode middle plate is shown on the right side. A cathode middle plate configuration is shown in the middle.

[0126] Fig. 17 shows an example embodiment of connector bars 230 for use in coupling adjacent modules of a stack. In this embodiment, the connectors are coupled via a pivot 232 connector joint configured to maintain structural and mechanical integrity of the stack. Pegs 234 are provided at ends of the connectors 230 for connections of the connector bars to the module plates or housings. A back view 236 of the connector bars shows the connector bars in a closed configuration. The length and thickness of the connectors can be consistent in the stack, but can range in other embodiments depending on the size of the air electrode modules. View 238 shows the connector bars in an open configuration. The distance that the connectors open may be dependent on the size of the modules and the connectors. A gap or opening space can be reflective of the needed spave for removal and reintegration of the metal air anode cartridges.

[0127] Fig. 18 shows an example embodiment of a single cell configuration 240. Each single cell configuration comprises two complete cathode backplate modules, an aluminum cartridge, connectors for modules, and additional components to help facilitate the mechanical refuel process. Each of the components seen in the single cell configuration are defined in the multi-cell configurations in Figs. 19 and 20. For an Aluminum-air battery cell, for example, the single cells may have an operational voltage between 1-1 .6 V.

[0128] Fig. 19 shows an embodiment of a six-cell multi-cell stack configuration 250. The multi-cell configuration is made up of multiple single cells. The multi-cell stack configurationincludes two cathode back plate modules and a defined number of cathode middle plate modules between the two back plates. The number of cells can depend on the output voltage, power, and energy needs from the cell. Each cell has a metal anode cartridge between the modules and a bracket system for the deployed stack. The stack is compressed to a pressure needed to eliminate the leakage of gas or electrolyte from the cell configurations. The brackets house the stack components and mechanical movement of the stack during refuel processes.

[0129] A single-sided cathode back plate module 251 includes integrated components. An metal anode cartridge (e.g., an aluminum cartridge) 252 is provided adjacent to the back plate module 251 . A double-sided cathode middle plate module 253 also includes integrated components and is disposed adjacent to the cartridge 252. Connectors 254 are configured to connect the modules 251 and 253. A wheel 255 is configured to attach to a bracket on the cathode module to aid with module movement during a mechanical refuel process. A bracket 255 is configured to house the stack components and mechanical movement of the stack.

[0130] Fig. 20 shows additional views of the six-cell multi-cell stack configuration of Fig. 19.

[0131] Fig. 21 shows an example embodiment of an aluminum air battery comprising a modular structure. The battery comprises a battery stack of cells organized into an array of rows and columns. Each cell comprises a base enclosure including a semi -permanent and permanent materials. The semi-permanent materials comprise a cathode modules including a cathode flow field, an air electrode, and a membrane. The cathode modules comprise inlet and outlet ports for a designated gas flow. The modules can be integrated into a base enclosure in varying numbers and sizes depending on needed output parameters. The permanent materials include an external cell casing and a flow distribution system system for the circulation and removal of electrolyte. A second component is an aluminum rod, in electrical contact with an anodic current collector, which together are inserted or removed by rack into (or from) the base enclosure, leaving room for annular flow field between the aluminum rod and cathode modules. The aluminum rods can vary in number and size like the cathode modules. The aluminum rods can vary in number and size like the cathode modules depending on the desired application. Proper tolerance for aluminum rod clearance will be maintained for mechanical recharge viability. The third component is a lid apparatus which supports annular electrolyte and gas in (or out) of the cathode modules. To support an entire stack, a heated electrolyte reservoir provides reactants to the internal cell housing via a pumping system. Asecondary reservoir contains standby corrosion inhibitor. A gas tank is responsible for delivery of air (or oxygen) to the cathode modules. The outlet gas can either be exhausted after a single pass or maintained within the module until consumed with a dead-end design.

[0132] Fig. 22 shows a battery module system comprising an array of aluminum air cells with N number of rows and M number of columns. The number of cells can vary dependent on the power, energy, and voltage requirements of the battery system. Each cell can be placed into a holder. The module also comprises a gas tank containing oxygen or air that is responsible for delivery of gas to the cathode. The module also comprises two liquid reservoirs. An alkaline electrolyte and corrosion inhibitor in one tank and a fluid used to mitigate aluminum corrosion during battery standby or shut off. The module also includes a pumping system for the delivery of electrolyte and standby fluid.

[0133] Figs. 23 and 24 show example electrolyte flow fields 270 and 280 that may be used within one or more air electrode modules to direct electrolyte across one or more surface of a metal anode cartridge. These are merely examples of possible electrolyte flow fields that may be used. In the example shown in Fig. 23, for example, the electrolyte flow field 270 comprises electrolyte inlet(s) 272 and outlet(s) 274 and a frame 276 defining an opening 278 for electrolyte flow across a surface of an adjacent metal anode cartridge. In the example shown in Fig. 24, for example, the electrolyte flow field 280 comprises electrolyte inlet(s) 282 and outlet(s) 284 and a frame 286 defining an opening 288 for electrolyte flow across a surface of an adjacent metal anode cartridge.

[0134] In some embodiments, a metal-air battery comprises a modular base enclosure configured to receive one or more metal anode cartridges (e.g., aluminum rods) in electrical contact with anodic current collectors. An annular flow field is defined between each aluminum rod and the adjacent cathode module, permitting circulation of electrolyte. The enclosure includes semipermanent cathode modules with integrated cathode flow fields, membranes, and gas manifolds, and permanent components such as an external casing and fluid distribution system. Fluid management for this or any other embodiments can comprise a heated electrolyte reservoir, a secondary corrosion inhibitor reservoir, and a pumping system for circulation of electrolyte and inhibitor fluids, as well as a gas tank configured to supply air or oxygen to the cathode modules.

[0135] In some embodiments, the system includes an accordion-style modular architecture in which modules are connected by pivotable or scissor-like connectors that allow the stack to expandand retract. Expansion of the stack exposes one or more metal (e.g., aluminum) anode cartridges for removal and replacement. The connectors may be configured as X-linkages, parallel bars with pivot joints, or hinged elements integrated into module housings. Such mechanisms facilitate mechanical recharge by cartridge replacement without disassembly of the stack. Prototypes employing ABS flow fields with serpentine, straight, or wave-shaped channels may be used to provide variations in limiting current density and flooding management.

[0136] In some embodiments, a system architecture may comprise arrays of cells arranged in N by M configurations. Each cell comprises cathode back plate modules and, in some cases, doublesided middle plate modules. Modules may be configured with male and female interlocking structures for alignment and stacking. Connector bars with pivot joints and locking pegs couple adjacent modules to maintain compression and structural integrity. Manifolds integrated into the modules allow for gas delivery, electrolyte circulation, and removal of spent gases. Brackets and guides facilitate accurate alignment and mechanical refueling of cartridges during stack expansion and closure.

[0137] Various embodiments are shown and described with reference to the drawings. The different embodiments highlight different concepts, structures, and methods that can be applicable to each of the different embodiments even though they are described for ease of understanding with respect to one or more specific embodiments. Although one or more concepts, structures, or methods may be described or shown with respect to one or more specific embodiments, those concepts, structures, and methods are contemplated to be useful across all or a portion of the embodiments in which they may be relevant.

Claims

CLAIMSWhat is claimed is:

1. A method of refueling a metal-air battery, the method comprising: providing a metal-air battery comprising: a first electrode module; a second electrode module; and a metal anode cartridge disposed between the first electrode module and the second electrode module, wherein the first and second electrode modules are coupled together to secure the metal anode cartridge between the first and second electrode modules to provide at least one metal-air battery cell; moving at least one of the first electrode module and the second electrode module relative to each other to expose the metal anode cartridge in an open configuration; extracting the metal anode cartridge from between the first electrode module and the second electrode module; disposing a second metal anode cartridge between the first electrode module and the second electrode module; closing the first electrode module and the second electrode module about the second metal anode cartridge to secure the second metal anode cartridge between the first electrode module and the second electrode module in a closed operational configuration.

2. The method of claim 1, wherein the first electrode module comprises a housing at least partially enclosing an electrode and an electrolyte flow field.

3. The method of claim 2, wherein the electrolyte flow field is in communication with a side of the metal anode cartridge in the closed operational configuration.

4. The method of claim 1, wherein the connector comprises a pair of pivotable members arranged in an X-configuration to permit opening and closing of the battery.

5. The method of claim 1, wherein the connector comprises at least one member extending between the first and second electrode modules.

6. The method of claim 1, wherein the connector comprises at least one lock, snap, clip, pin, bolt, nut, and / or quick-release connector configured to secure the first and second electrode modules in the closed operational configuration.

7. The method of claim 1, wherein the step of disposing the second metal anode cartridge further comprises automatically releasing electrolyte from a manifold to the cartridge upon insertion.

8. The method of claim 1, wherein the metal anode cartridge comprises aluminum, zinc, magnesium, or alloys thereof.

9. The method of claim 1, wherein the metal-air battery comprises a gas manifold configured to deliver air or oxygen to the electrode.

10. The method of claim 1, further comprising draining electrolyte before extraction of the metal anode cartridge.

11. The method of claim 1, further comprising passively draining electrolyte by removing the metal anode cartridge.

12. The method of claim 1, further comprising draining electrolyte into a manifold compartment before extraction of the metal anode cartridge.

13. The method of claim 1, wherein the first and second electrode modules each comprise a gas diffusion layer and a catalyst layer.

14. The method of claim 1, wherein the connector comprises parallel link bars coupled between the first and second electrode modules.

15. The method of claim 1, wherein at least one of the first and second electrode modules comprises a double-sided electrode configured to form two distinct metal -air cells.

16. The method of claim 1, wherein a plurality of metal anode cartridges are disposed between the first and second electrode modules.

17. The method of claim 1, wherein the metal anode cartridge is received in a bracket configured to align the cartridge during removal and insertion.

18. The method of claim 1, wherein at least one of the first and second electrode modules comprises a male side and a female side for interdi itation with additional modules in a stackable manner.

19. The method of claim 1, wherein the first electrode module comprises a male-type housing and the second electrode module comprises a female-type housing for stackable interconnection.

20. The method of claim 1, wherein at least one of the first and second electrode modules comprises a double-sided module in which an air electrode is disposed in either side of the module.

21. A manually rechargeable metal-air battery comprising: a first electrode module comprising a first housing partially enclosing a first electrode and a first electrolyte flow field; a second electrode module comprising a second housing partially enclosing a second electrode and a second electrolyte flow field; a metal anode cartridge disposed between the first and second electrolyte flow fields in a first closed operational configuration; and a connector coupling first housing to the second housing, the connector configured allow the first electrode module to move relative to the second electrode module to expose the metal anode cartridge for removal and replacement with a second metal anode cartridge, and to return the first electrode module and the second electrode module about the second metal anode cartridge in the first closed operational configuration.

22. The battery of claim 21, wherein the first electrode module comprises a housing at least partially enclosing an electrode and an electrolyte flow field.

23. The battery of claim 22, wherein the electrolyte flow field is in communication with a side of the metal anode cartridge in the closed operational configuration.

24. The battery of claim 21, wherein the connector comprises a pair of pivotable members arranged in an X-configuration to permit opening and closing of the battery.

25. The battery of claim 21, wherein the connector comprises at least one member extending between the first and second electrode modules.

26. The battery of claim 21, wherein the connector comprises at least one lock, snap, clip, pin, bolt, nut, and / or quick-release connector configured to secure the first and second electrode modules in the closed operational configuration.

27. The batery of claim 21, wherein the step of disposing the second metal anode cartridge further comprises automatically releasing electrolyte from a manifold to the cartridge upon insertion.

28. The battery of claim 21, wherein the metal anode cartridge comprises aluminum, zinc, magnesium, or alloys thereof.

29. The battery of claim 21, wherein the metal-air battery comprises a gas manifold configured to deliver air or oxygen to the electrode.

30. The battery of claim 21, wherein the metal-air battery comprises a drain configured to drain electrolyte before extraction of the metal anode cartridge.

31. The battery of claim 21, wherein the metal-air battery comprises a drain configured to passively drain electrolyte by removing the metal anode cartridge.

32. The battery of claim 21, wherein the metal-air battery comprises a drain configured to drain electrolyte into a manifold compartment before extraction of the metal anode cartridge.

33. The battery of claim 21, wherein the first and second electrode modules each comprise a gas diffusion layer and a catalyst layer.

34. The battery of claim 21, wherein the connector comprises parallel link bars coupled between the first and second electrode modules.

35. The battery of claim 21, wherein at least one of the first and second electrode modules comprises a double-sided electrode configured to form two distinct metal-air cells.

36. The batery of claim 21, wherein a plurality of metal anode cartridges are disposed between the first and second electrode modules.

37. The battery of claim 21, wherein the metal anode cartridge is received in a bracket configured to align the cartridge during removal and insertion.

38. The battery of claim 21, wherein at least one of the first and second electrode modules comprises a male side and a female side for interdigitation with additional modules in a stackable manner.

39. The battery of claim 21, wherein the first electrode module comprises a male-type housing and the second electrode module comprises a female-type housing for stackable interconnection.

40. The batery of claim 21, wherein at least one of the first and second electrode modules comprises a double-sided module in which an air electrode is disposed in either side of the module.

41. The battery of claim 21, wherein the metal-air battery comprises an aqueous electrolyte.

42. The method of claim 1, wherein the metal-air battery comprises an aqueous electrolyte.

43. The method of claim 1, wherein at least one of the operations of extracting the metal anode cartridge and disposing a second metal anode cartridge is performed automatically.

44. The method of claim 43, wherein the at least one of the operations of extracting the metal anode cartridge and disposing a second metal anode cartridge is performed via one or more robots.

45. A compound metal-air battery system comprising: a plurality of electrode modules including a pair of end unit electrode modules; at least one replaceable metal anode cartridge disposed between adjacent electrode modules; and at least one connector configured to permit selective opening of the system to remove and replace one or more of the metal anode cartridges.

46. The battery system of claim 45, wherein the plurality of electrode modules comprises at least one double-sided electrode module disposed between the pair of end unit electrode modules.

47. A refueling kit for a mechanically rechargeable metal-air battery, the kit comprising: a plurality of metal anode cartridges; and a metal-air battery comprising: a plurality of electrode modules including a pair of end unit electrode modules; and at least one connector configured to permit selective opening of the system to remove and replace one or more of the metal anode cartridges.

48. The refueling kit of claim 47, wherein the plurality of electrode modules comprises at least one double-sided electrode module disposed between the pair of end unit electrode modules.battery manifold assembly configured to drain electrolyte from a cell during removal of an anode cartridge and to release electrolyte upon insertion of a replacement anode cartridge.

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