Metal-air battery system with recharging, and use thereof

Abstract

The present invention relates to a rechargeable integrated system for generating electric current for metal-air batteries, preferably aluminium-air batteries, comprising: a perforated compartment (2) for retaining metal grains (anode), providing the electrical contact required for generating energy with the exterior of the battery and selective passage of electrolyte and by-products; a cathode (5); an electrolyte recirculation circuit with a recirculation pump (1) and a filtration system (6); and an external recharging system with an integrated filling and discharge nozzle (9), a filling pump (10), a filling reservoir (11) and a recovery tank (12). The system operates in two modes: continuous operation, in which the electrolyte circulates through the perforated compartment and filtration system; and recharging, in which new metal grains and electrolyte are injected under pressure while by-products are removed. The system eliminates the need to disassemble the battery for recharging, using the electrolyte as a transport medium for the grains and as a cleaning agent for removing by-products. It optionally includes a local tank (13) for controlled metering of grains and water / electrolyte, valves for flow control (7, 8), and may be adapted for different arrangements and types of metal-air batteries.

Description

Integrated system for generating rechargeable electric current, product obtained and its use. BRIEF DESCRIPTION

[0001] The present invention describes an "INTEGRATED RECHARGEABLE ELECTRIC CURRENT GENERATING SYSTEM, PRODUCT OBTAINED AND ITS USE", specifically applied to metal-air batteries, preferably aluminum-air, characterized by a mechanism for rapid and continuous anode refilling and electrolyte management. The system essentially comprises a battery cell with an internal perforated compartment (PE) that retains aluminum grains (anode) and allows the selective passage of electrolyte and byproducts; an air cathode; an electrolyte recirculation circuit driven by a pump, which maintains the flow of electrolyte through the PE and a filtration system for removing byproducts (mainly Al(OH)s); and an external refilling circuit.The system operates by allowing the pressurized injection of the grain and electrolyte mixture through the nozzle, using the electrolyte itself as a carrier fluid, while simultaneously removing byproducts to the recovery tank, enabling recharging without disassembling the battery. FIELD OF APPLICATION

[0002] The present invention relates to electrochemical energy storage systems, focusing on metal-air batteries, preferably aluminum-air batteries, developed for applications in electric vehicles, stationary power systems, and portable devices. The invention presents an innovative system that enables rapid anode replenishment through the injection of aluminum granules and electrolyte recirculation, eliminating the need to disassemble the battery for recharging. Furthermore, the replenishment system can be adapted to other metal-air batteries that use anode replacement as a recharging mechanism, expanding its applicability and improving operational efficiency in various technologies. CONVINCING

[0003] Aluminum-air batteries have an extremely high theoretical energy density, reaching up to 8,100 Wh / kg, far surpassing other technologies such as lithium-ion batteries. In practice, this number is significantly lower due to limitations related to efficiency and losses. Even so, these batteries offer much higher practical energy densities than lithium-ion batteries, which reach lower values ​​(~250-300 Wh / kg), making them ideal for applications requiring high energy density, such as electric vehicles and large-scale energy storage systems.

[0004] Despite these energy advantages, traditional aluminum-air batteries require total or partial disassembly of the system for anode replacement, which limits their practical application, especially in scenarios that demand continuous operation, such as electric transport and energy storage. Furthermore, conventional systems have difficulties in the efficient removal of byproducts, such as Al(OH)3, which can clog the system and reduce battery efficiency.

[0005] Currently available solutions utilize solid anodes and static electrolytes, which makes replenishment and byproduct management difficult. To date, there is no solution that combines rapid aluminum replenishment with an efficient filtration and byproduct removal system in a compact and practical design.

[0006] The present invention overcomes these limitations by allowing rapid replenishment of the aluminum anode without the need to disassemble the battery. This is done through a system that injects a mixture of aluminum grains and electrolyte while simultaneously removing the generated byproducts (Al(OH) and others). This approach provides greater practicality and operational efficiency, significantly expanding the scope of applications for metal-air batteries, preferably aluminum-air batteries.

[0007] Furthermore, the developed system is adaptable to other metal-air batteries that rely on replacing the metal anode as a recharging mechanism. In these configurations, the anode can be replaced with grains of the corresponding material, similarly to how it works with aluminum, optimizing performance and extending the lifespan of batteries in various technological applications. BACKGROUND OF THE INVENTION

[0008] Prior art document US 2016 / 0020498 A1 describes a metal-air battery applicable to various metals including aluminum (Al), zinc (Zn), lithium (Li), sodium (Na), calcium (Ca), magnesium (Mg), and iron (Fe). The presented configuration comprises an electrochemical cell containing a tank for the electrolyte, a metal electrode acting as an anode and insertable into the tank, and an air electrode functioning as a cathode. The system provides a specific opening for the insertion and removal of the consumed metal electrode, allowing for anode replacement. Additionally, the prior art document contemplates the possibility of including an ion-exchange membrane between the electrodes. For the management of the electrolyte and reaction byproducts, the document describes electrolyte circulation mechanisms, which can be implemented through a pump or by means of mobile components such as stirrers or vibrators, aiming to physically move the electrolyte solution within the tank.The prior art document also discloses a system for recovering the precipitated active material (metallic byproduct), which may include a flow circuit for the electrolyte, a dedicated recovery tank for the precipitate, and a filtration section to separate the solids from the pumped electrolyte solution.

[0009] In comparison with the present application, the prior art document, while describing a metal-air battery with electrolyte circulation and byproduct recovery, differs substantially in critical aspects relating to the anode replenishment method and the internal cell architecture. Firstly, the prior art document does not anticipate the internal perforated element (PE) presented in the present application, a multifunctional structure designed to retain the aluminum grains while allowing controlled passage of electrolyte and fine byproduct particles, as well as optimizing electrical contact and electrolyte distribution between the grains.Secondly, the replenishment method in the prior art document involves the manual or mechanical replacement of a metallic electrode (possibly in block or plate form), contrasting with the system of the present application which uses the pressurized injection of aluminum granules transported by the electrolyte itself through a dedicated external circuit, allowing for rapid and potentially continuous replenishment without the need for a... The need to open the cell. The electrolyte circulation in the document is primarily aimed at thermal management and precipitate removal, not acting as an active vector for the insertion of the anodic material as proposed in the invention. Finally, the prior art neither describes nor suggests the integrated external and pressurized charge / discharge interface that characterizes the rapid refueling system of the present application.

[0010] US patent 3847671 A describes a non-polarized metal-gas battery that can use various metals as anodic material, including aluminum (Al), zinc (Zn), lithium (Li), magnesium (Mg), cadmium (Cd), or iron (Fe), and different gases for the cathode, such as air, oxygen, or others. The central feature of the patent lies in the use of the active metal in powder form, which is mixed with the electrolyte to form a paste or slurry. This mixture is then poured into a compartment inside each battery cell, defined by a negative grid (collector), a separator, and the cell walls and bottom. The system provides for connection to an external storage tank, to which the cell contents (electrolyte, particulate byproducts, and unconsumed metal powder) are transferred for an external recharging process. The cells are then replenished with new active metal paste and electrolyte.The anterior design includes ports for removing discharged compounds, adding fresh material, draining excess electrolyte, and circulating the electrolyte through the cells to clean them of discharge products. The aforementioned circulation system may include a pump and a filter. The negative grid is designed with openings small enough to act as a filter, retaining solid particles within the cell.

[0011] In relation to the present application, the document presents significant differences, particularly concerning the form of the anodic material and the refilling method. The document uses a metallic powder mixed with the electrolyte to form a paste (slurry), which is introduced into the cell. This method contrasts directly with the use of aluminum grains of controlled size in the present application, which are retained by the perforated element (PE) and allow the active circulation of the electrolyte between them. The refilling process in the prior art requires complete drainage of the cell to remove the used paste and the introduction of a new mixture, a discontinuous process. and which interrupts battery operation. The present application, on the other hand, describes a rapid and potentially continuous refilling system where the grains are injected through an external circuit using the electrolyte itself as a carrier fluid, without the need for drainage or prolonged downtime. Additionally, the prior art does not describe a structure analogous to the multifunctional PE of the present application, which is essential for retaining the grains, allowing the selective flow of electrolyte and byproducts, and optimizing electrical contact. The aforementioned grid acts as a simple filter to retain solid particles, without the specific hydraulic and electrical functions of PE. Finally, the prior art does not contemplate the use of the electrolyte as an active transport medium for the anodic material during refilling, nor an integrated interface for external and pressurized charging / discharging.

[0012] US patent 2023 / 0369683 A1 describes a metal-carbon dioxide (metal-CO2) battery designed for continuous supply of anodic material without the need for disassembly. The structure includes a set of plates (first and second) with inlets and outlets for the electrolyte, a separator positioned between them, and a joint that creates a space (gap) where the anodic material, in the form of pellets or granules (with a suggested diameter between 3 and 10 mm), is received. The system may incorporate a support, such as an oblique plate with through holes (suggested diameter of 0.5 to 2 mm, smaller than that of the anodic material), to contain the anode in the defined space. Potential anodic materials include indium (In), copper (Cu), magnesium (Mg), aluminum (Al), stainless steel, and iron (Fe). The cathode, positioned between the second plate and the separator, may be made of materials such as carbon paper or metal foam and may include catalysts.The broader system described above aims at generating hydrogen and storing carbon dioxide (in salt form), integrating the metal-CO2 battery with electrolyte supply units, hydrogen gas separation, and CO2 recovery.

[0013] In contrast to the present application, the prior art document, although describing a system with continuous feeding of anodic material in pellet form (similar to grains) and a structure with holes for retaining this material, presents fundamental differences. Firstly, the document refers to a The metal-carbon dioxide (metal-CO2) battery, an electrochemical system distinct from the aluminum-air battery of the present application, has different objectives and byproducts (H2 generation and CO2 storage). Secondly, the anode feeding method in the prior art, although continuous, does not describe the pressurized injection of the grains using the electrolyte as a carrier fluid through an external circuit, a central feature of the rapid replenishment system of the present application. The feeding appears to occur by gravity or another mechanism not detailed that does not involve the active and multifunctional function of the electrolyte as a transport, cleaning, and simultaneous ionic conduction agent, as proposed in the invention.Furthermore, the perforated retention structure in the prior art, while functionally similar in retaining the anodic material, is not described with the multifunctional characteristics of the perforated element (PE) of the present application, which optimizes electrical contact and hydraulic flow specifically for aluminum grains and circulating electrolyte. Finally, the document does not anticipate the integrated external load / discharge interface and the use of the electrolyte circuit to perform active refilling and simultaneous cleaning of the system.

[0014] US patent 4490443 A discloses a metal-air battery, specifically exemplified with aluminum as the consumable anode. The described configuration involves cells that utilize a flat, rectangular metal electrode positioned within a receptacle that is flushed with alkaline electrolyte. Each receptacle also supports gas diffusion electrodes (air cathodes) arranged on the flat sides of the receptacle. The system includes a reservoir for the electrolyte supply, located below the cell unit, and a pump with distribution lines to supply the electrolyte from the reservoir to each cell receptacle. Recharging the system, as described, is based on the physical replacement of the consumed flat aluminum electrode with a new one. The used electrolyte is returned to the supply container along with the used electrodes.Although it mentions the recirculation of electrolyte through a pump and reservoir, the main purpose of this circulation is to supply fresh electrolyte to the cells and remove used electrolyte, and it is not associated with a mechanism for replenishing the metal anode itself during operation or through the injection of anodic material.

[0015] Finally, in comparison with the present application, the document describes an aluminum-air battery with a flat anode that requires manual physical replacement, a fundamentally different replenishment method from the proposed aluminum granule injection. While the prior art mentions the circulation of electrolyte from a reservoir, this function is limited to supplying fresh electrolyte and removing used electrolyte, not contemplating the use of the electrolyte as an active transport medium for the anodic material nor for the simultaneous cleaning of the system, as claimed. The present application introduces a system where the electrolyte is pumped through an external circuit, charging and injecting the aluminum granules directly into the reactive zone, a concept absent in the prior art.Additionally, the prior art neither describes nor suggests an internal structure comparable to the perforated element (PE) of the present application, which plays a crucial role in grain retention, optimization of electrical contact, and management of electrolyte and byproduct flow. The absence of a fast, pressurized, and integrated replenishment system that uses the electrolyte as a multifunctional vector clearly distinguishes the present application from the technology described in the document. OBJECTIVES OF THE INVENTION

[0016] The main objective of this invention is to provide an innovative system for metal-air batteries, preferably aluminum-air batteries, that overcomes the limitations of conventional technologies, particularly regarding the anode refueling process and the management of reaction byproducts. Specifically, it seeks to eliminate the need to disassemble the battery to replace the consumed aluminum anode, allowing for rapid refueling, comparable to that of liquid fuels, through the injection of aluminum granules transported by the electrolyte itself in a dedicated circuit. Additionally, it aims to integrate into this process an efficient electrolyte recirculation system and continuous filtration of generated byproducts, such as aluminum hydroxide (Al(OH)3), ensuring the maintenance of battery performance and extending its operational lifespan.The invention therefore aims to enable the practical and large-scale application of metal-air batteries, preferably aluminum-air batteries, taking advantage of their high theoretical energy density. sectors such as electric vehicles, stationary energy storage, and portable devices, offering a more efficient, practical, and adaptable energy solution for different metal-air battery configurations. OF THE INVENTION

[0017] The present invention relates to an integrated system and method for the operation and rapid replenishment of metal-air batteries, with particular application to metal-air batteries, preferably aluminum-air, aiming to overcome the practical limitations that restrict the use of these high-energy-density technologies. The prior art, while recognizing the potential of aluminum-air batteries, faces significant challenges related to the need for manual and time-consuming replacement of the consumed anode and the inefficient management of reaction byproducts, such as aluminum hydroxide, which can compromise battery performance and lifespan. The invention proposes a technical solution that directly addresses these problems by introducing a system that allows the replenishment of the aluminum anode, in granular form, without the need to disassemble the battery cell. ADVANTAGES

[0018] The present invention offers several significant advantages over metal-air batteries, preferably aluminum-air batteries, overcoming technical and operational limitations of the prior art. The main advantage lies in the fast and potentially continuous refueling system, which eliminates the need to disassemble the battery to replace the anode, drastically reducing downtime (to less than five minutes, comparable to refueling combustion vehicles) and increasing the practicality and availability of the system. The use of the electrolyte as a vector to transport and inject the aluminum granules directly into the reactive zone, combined with the simultaneous removal of byproducts through an integrated external circuit, represents an innovative approach that optimizes recharging logistics.

[0019] Another advantage is the improved management of byproducts, such as Al(OH)3. The continuous electrolyte recirculation system through a perforated compartment (PE) and a dedicated filtration system allows for the efficient removal of these byproducts. Preventing cell clogging, maintaining electrochemical performance, and extending battery life. The PE structure is multifunctional, ensuring not only grain retention but also optimizing electrical contact and electrolyte distribution, which contributes to greater efficiency and practical energy density (reported between 1,200 and 1,300 Wh / kg, significantly higher than the 250-300 Wh / kg of traditional systems).

[0020] Additionally, the system offers flexibility and adaptability, being compatible with different aluminum grain sizes, various electrolyte compositions (including mixtures with alcohols to reduce corrosion), and configurations with or without a separator membrane. The architecture can be scaled for compact or large-scale stationary applications. The possibility of adapting the system for other metal-air batteries that use anode replacement expands its application potential.

[0021] The optional inclusion of a local tank for controlled grain and water / electrolyte dosing allows for maintaining consistent battery performance and customizing system runtime. DESCRIPTION OF THE FIGURES

[0022] In order to better explain the present invention, reference will be made to the following figures: FIG. 1 presents the general scheme of the INTEGRATED RECHARGEABLE ELECTRIC CURRENT GENERATOR SYSTEM, THE PRODUCT OBTAINED AND ITS USE; FIG. 2 presents the general scheme of the INTEGRATED RECHARGEABLE ELECTRIC CURRENT GENERATOR SYSTEM, the PRODUCT OBTAINED, and its use in its variation. DETAILED DESCRIPTION

[0023] The proposed system is composed of several components that operate in an integrated manner to ensure the efficient functioning of a metal-air battery, preferably aluminum-air. The recirculation pump (1) plays an essential role in maintaining a constant flow of electrolyte, ensuring the recirculation of materials and the transport of byproducts. The perforated compartment (PE) (2), located at the anode of the battery, retains the aluminum grains, allowing the passage of Al(OH)3, electrolyte and smaller particles while making the necessary electrical contact for energy generation with the outside of the battery. The electrolyte circulates in the electrolyte compartment (3), a dedicated compartment that directs the Al(OH)s formed during the reactions to the filtration system.

[0024] The battery structure is protected by the battery compartment (4), which provides mechanical isolation to the internal components. The cathode (5) is responsible for reducing oxygen, completing the electrochemical reaction and allowing the generation of electricity. After its circulation in the system, the electrolyte passes through the filtration system (6), which separates solid byproducts, such as Al(OH)se, small particles of aluminum that are not yet oxidized, allowing the clean electrolyte to be recirculated. This filtration system can also be configured to separate small grains of aluminum from the remaining byproducts, allowing their recirculation to the anode.

[0025] Flow management is achieved through the On / Off valve (7), which controls the electrolyte flow, and the check valve (8), which ensures unidirectional flow during refilling. The integrated loading and unloading nozzle (9) plays the crucial role of facilitating the entry of new metal and electrolyte granules into the system, as well as allowing the simultaneous removal of generated byproducts. This nozzle, in both configurations, has a mechanism that allows its automatic opening and closing, respectively, when the external supply hose is connected or disconnected. The loading pump (10) injects new metal and electrolyte granules from the loading reservoir (11), which functions as a storage tank for the material needed for refilling. Byproducts, such as Al(OH)3 and consumed aluminum particles, are collected in the recovery tank (12), where they can be disposed of or recycled.

[0026] The system operates in two distinct modes. In continuous operation mode, the recirculation pump (1) maintains the electrolyte flow, concentrating the aluminum grains in the perforated compartment (PE) (2) and allowing the Al(OH)s to pass into the electrolyte compartment (3). In this compartment, the Al(OH)s settles and is carried to the filtration system (6), where it is separated and removed, allowing the Clean electrolyte returns to the system. During refueling mode, the On / Off valve (7) is closed to stop recirculation, and the check valve (8) allows new materials to enter through the integrated loading and unloading nozzle (9). The loading pump (10) injects new aluminum granules and electrolyte from the loading reservoir (11), while spent materials are directed to the recovery tank (12) for storage or recycling.

[0027] The loading reservoir (11) and the recovery tank (12) may form part of a single structure with a movable central wall to separate new material from used material. This wall would allow maximum volume for new material as soon as the tank is replenished and maximum volume for used material when the tank is empty of new material. The replenishment system may have an agitation system to prevent the pellets from settling to the bottom of the tank or a metering pump to allow them to be captured from the bottom and metered into the electrolyte stream.

[0028] The system may have an extra tank, therefore presenting two variations with and without the local tank (13). The local tank (13) stores the additional aluminum grains, water, and dissolved electrolyte to compensate for any losses during reactions that do not form Al(OH)s. Water is necessary to maintain the proper dilution of the electrolyte within the cell, since the chemical reaction consumes water, tending to increase the electrolyte concentration. Optionally, additives may be added to the water in the local tank to reduce hydronium formation and aluminum corrosion. This tank has a filter at its outlet, designed to allow only water and dissolved additives to pass through, retaining the aluminum grains inside the tank. A branch from the main piping is created in this configuration, forming an external pipe that connects the outlet of the local tank (13) directly to the inlet of the filtration system (6).This external circuit is used specifically during the replenishment process of the local tank (13) and for cleaning the filtration system (6). To perform this replenishment / cleaning, the check valves (8) are closed, isolating the main cell. The mixture of aluminum and water (with possible additives) is then circulated through this external piping (passing through the filter at the outlet of the local tank (13) which retains the aluminum) and through the filtration system. (6), allowing the removal of by-products accumulated in the filter and the replenishment of water / additives in the main circuit, or the replenishment of aluminum / water in the local tank from an external source through the nozzle (9) or other dedicated connection. Operating Modes:

[0029] Continuous Operation (both configurations): The recirculation pump (1) maintains the flow of electrolyte through the cell (PE (2), compartment (3), cathode (5)) and the filtration system (6). In the configuration with local tank, the injector (14) doses aluminum as needed.

[0030] External Replenishment (both configurations): The check valves (8) can be closed or managed as needed. The loading pump (10) injects new material from the loading reservoir (11) through the nozzle (9), while spent material is directed to the recovery tank (12).

[0031] Local Tank Refilling / Cleaning (local tank configuration (13) only): The check valves (8) are closed. The aluminum and water mixture is circulated through the external piping (Tank 13 > Filter 6) for cleaning and / or refilling the local tank.

[0032] The grains can be dosed into the electrolyte flow to maintain a constant area of ​​aluminum exposed to the reaction. This will be used to keep the battery voltage and amperage constant and can even increase and / or customize the system's autonomy by having more "fuel" stored in the system. Thus, the volume of aluminum in the battery will be lower initially, but will remain constant, and the total volume of the system can be equal to or greater than the original volume of the battery.

[0033] In this tank, in addition to the grains, water (or an electrolyte more dissolved in water than that used for the reaction) will be added because the reaction consumes water from the electrolyte, making it increasingly concentrated. This can help in introducing this water and grain mixture into the system by pressure.

[0034] The tank would function like a regular fuel tank; that is, it could be filled to a certain level, and from there a small pump would send the electrolyte mixture pellets into the battery.

[0035] This integrated design offers an efficient solution for extending the service life of metal-air batteries, preferably aluminum-air batteries, eliminating the need for disassembly for refilling and ensuring high energy efficiency in applications that demand continuous operation.

[0036] The proposed system offers several implementation possibilities to meet different needs and applications. The perforated compartment (2) can be manufactured from corrosion-resistant materials, including but not limited to metals, polymers, graphite, ceramics, or composite materials, depending on the operating environment. The orifices can have variable dimensions, optimizing electrolyte flow and aluminum granule retention. The filtration system (6) can be configured with multiple stages, such as mechanical filters, cyclones, or decanters, to efficiently separate Al(OH)se smaller aluminum particles. Furthermore, it can include mechanisms to recover partially consumed aluminum granules, maximizing material efficiency. The recovered aluminum granules also served as an abrasive to remove already oxidized aluminum from the granule surfaces within the perforated compartment (2) and increase the overall efficiency of the battery.

[0037] The system is compatible with different electrolyte compositions, such as diluted KOH solutions mixed with alcohols (ethanol, methanol or ethylene glycol), or other solutions, which reduce corrosion and improve efficiency. It can be implemented with or without a separating membrane between the anode and cathode, depending on the application requirements. The recovery tank (12) may include additional sections to separate solids, facilitating the disposal or recycling of by-products.

[0038] Due to the size of the pumping, circulation, and filtration system, the aluminum granules to be injected into the battery can vary, with smaller sizes being used in applications for compact equipment and larger sizes intended for stationary applications, such as energy storage. For the latter, the system design can be expanded to support larger volumes of electrolyte and aluminum, optimizing energy storage capacity. These characteristics They make the system flexible and adaptable to diverse demands, maximizing its applicability and efficiency.

[0039] The present invention offers an innovative and practical solution for metal-air batteries, preferably aluminum-air batteries, integrating rapid refilling, electrolyte recirculation, and efficient byproduct management. With high energy density and flexibility for different configurations, the system solves the main challenges of conventional batteries, expanding their applicability in scenarios that demand continuous operation, high efficiency, and long lifespan.

[0040] Other metal-air batteries that rely on anode replacement can benefit from the rapid refilling and electrolyte recirculation system of the present invention, increasing their efficiency and application possibilities. Although aluminum-air batteries, with a high theoretical energy density of 8,140 Wh / kg, stand out for their competitive cost and availability of aluminum, the system can also be adapted to other metal-air batteries, optimizing anode use and extending the system's lifespan. In these applications, the byproducts generated will be specific to the metal used, replacing aluminum derivatives. EXAMPLES OF CONCRETIZATIONS OF THE INVENTION

[0041] The preferred embodiment of the present invention consists of a metal-air battery, preferably aluminum-air, configured with a rapid replenishment system that utilizes aluminum grains with dimensions between 500 µm and 1,000 µm. The electrolyte is based on a solution of KOH diluted with ethanol, a choice that reduces corrosion and improves efficiency. The perforated compartment is manufactured from corrosion-resistant technical polymer, such as PTFE, and has 30 µm orifices, allowing efficient flow of electrolyte and byproducts while retaining the larger grains. A recirculation pump is sized to ensure a constant flow of electrolyte, which prevents unwanted sedimentation and promotes the continuous removal of Al(OH)s.

[0042] The filtration system used in this embodiment includes a cyclone filter followed by a decanter, which efficiently separates byproducts before recirculating the electrolyte to the perforated compartment. During refilling, a nozzle The integrated system connects the battery to an external supply tank, which provides new aluminum granules and electrolyte, while directing consumed Al(OH)3 and particles to a recovery tank. This design significantly reduces refueling time, increasing practicality and efficiency, especially in mobile and stationary applications requiring high energy density and continuous operation.

[0043] Alternatively, the system can be configured to use smaller aluminum granules, preferably, but not limited to, 200 µm to 1000 µm, in applications requiring compact systems. In these cases, the perforated compartment would be fitted with 20 µm holes to ensure granule retention. The electrolyte can also consist of diluted KOH mixed with methanol or ethylene glycol, depending on operating conditions such as ambient temperature or low corrosivity requirements. In applications where mechanical robustness is a critical factor, the perforated compartment can be manufactured from graphite-coated 316L stainless steel, ensuring greater structural strength, even if the total weight of the system is slightly increased.

[0044] For stationary applications, where system complexity can be reduced, a single-stage filtration system using a mechanical filter may be sufficient to remove Al(OH)s. In systems requiring higher ion transport efficiency, an ion exchange membrane, such as Nafion, can be integrated between the anode and cathode, significantly increasing the overall system efficiency in applications requiring high energy density. In these systems, the aluminum grain size can be increased, extending its lifespan within the system and improving its overall utilization. This approach ensures greater operational stability and reduces the frequency of refilling, making it ideal for long-duration energy storage solutions.

[0045] Comparative tests conducted between the proposed system and traditional aluminum-air batteries demonstrate its superiority. While traditional systems with fixed anodes have practical energy densities between 250 and 300 Wh / kg, the proposed system achieves densities between 1,200 and 1,300 Wh / kg. Furthermore, the invention eliminates the need for disassembly to replace the anode, enabling... Rapid refueling with 95% efficiency and downtime of less than five minutes. These results demonstrate that the proposed system not only significantly increases practical energy density but also improves operational efficiency, making it ideal for practical applications requiring high reliability and continuous performance.

Claims

CLAIMS 1. INTEGRATED RECHARGEABLE ELECTRIC CURRENT GENERATOR SYSTEM FOR METAL-AIR BATTERIES, characterized by comprising: • a perforated compartment (2) configured to retain metal grains (anode) and allow selective passage of electrolyte and byproducts; • a cathode (5); • an electrolyte recirculation circuit comprising a recirculation pump (1) and a filtration system (6) for separating by-products; • an on / off valve (7) for controlling the flow of electrolyte; • a check valve (8) to ensure one-way flow during refueling; • an external refueling circuit comprising an integrated loading and unloading nozzle (9), a loading pump (10), a loading reservoir (11) for storing new metal grains and electrolyte, and a recovery tank (12) for collecting by-products.

2. SYSTEM, according to claim 1, characterized by having a variation comprising a local tank (13) for additional storage of metal granules, water and diluted electrolyte; an injector (14) configured to dose the granules with liquids.

3. SYSTEM, according to claim 1, characterized by the integrated loading and unloading nozzle (9) having an automatic opening and closing mechanism activated by the connection and disconnection of an external supply hose.

4. SYSTEM, according to claim 1, characterized in that the local tank (13) optionally contains additives.

5. SYSTEM, according to claim 1, characterized in that the anode metal is a metal, preferably, but not exclusively, aluminum.

6. SYSTEM, according to claim 1, characterized by allowing refueling without disassembling the system.

7. SYSTEM, according to claim 1, characterized in that the metal grains have preferred, but not limiting, dimensions between 200 pm and 1,000 pm.

8. SYSTEM, according to claim 1, characterized in that the perforated compartment (2) is manufactured from materials including, but not limited to, metals, polymers, graphite, ceramics or composite materials.

9. SYSTEM, according to claim 1, characterized by the perforated compartment (2) having holes with preferred, but not limiting, dimensions between 20 µm and 30 µm.

10. SYSTEM, according to claim 1, characterized by the perforated compartment (2) making the electrical contact necessary for power generation with the outside of the battery.

11. USE OF THE SYSTEM, according to claim 1, characterized by being employed in metal-air batteries for selected applications of the group comprising electric vehicles, stationary power systems and portable devices.

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