Split serpentine flow field plate, system and method

Abstract

A split serpentine flow field plate designed to improve electrolyte distribution in flow batteries is provided The flow field plate includes an inlet port for receiving a first electrolyte, multiple inlets (first, second, third, and fourth) to distribute the electrolyte to corresponding quadrants, and a drain canal to collect reacted electrolyte from each quadrant and direct it to an outlet port. Each quadrant features a serpentine-like flow channel. The design aims to overcome limitations of traditional serpentine flow fields, such as unfavourable pressure drop and uneven electrolyte distribution, thereby enhancing the efficiency of charge-discharge cycles in flow batteries.

Description

SPLIT SERPENTINE FLOW FIELD PLATE, SYSTEM AND METHODTECHNICAL FIELD

[0001] The present disclosure relates generally to an accumulator system and more particularly to a split serpentine flow field plate, system, and method.BACKGROUND

[0002] A reduction-oxidation flow battery or flow battery is a type of electrochemical cell where chemical energy is provided by two chemical components dissolved in liquids that are pumped through the system on separate sides of a membrane. The charge-discharge duty of the flow battery requires the circulation of electrolytes from external reservoirs through the cells. The flow battery includes a positive and negative porous electrode that are separated by a membrane.

[0003] The performance of the charge-discharge life cycle of a flow battery depends on the mechanism of circulation of electrolytes through the electrodes. The effective circulation to meet the desired electrochemical performance of a flow battery is attributed to the uniform distribution of reactant species across the electrode and quick evacuation of product species from the electrode region at low fluid traverse resistance. An uneven supply of electrolytes in the electrodes results in loss of performance. Significant attenuation of performance may be caused at high current densities due to insufficient replenishment or removal of species.

[0004] Flow field plate plays a vital role in the performance of the flow batteries as it distributes the electrolyte in the flow batteries. These flow field plates are made of a suitable electrically conducting material and serve as current collectors to provide electrical continuity between the cell voltage terminals and electrodes.

[0005] The serpentine flow field is one among several flow field variants that has been investigated significantly for application in electrochemical cells.

[0006] Serpentine flow channels traverse continuously from inlet to outlet with several hairpin turns and switchbacks by covering the entire area of the electrode thus providing electrolyte species across all the active sites of the electrode.

[0007] The limitations associated with the currently available serpentine flow are that a long flow path with several turns typically involves a large unfavourable pressure drop between the inlet and outlet which translates to significant parasitic power consumption, poor replenishment removal of reactant and product species, respectively, and long flow channels results in high reactant gradient from inlet to outlet leading to over-potential losses and ineffective utilization of active sites of electrode thus reducing the efficiency of a charge-discharge life cycle.

[0008] Another available flow field plate with a serpentine configuration includes an openfaced fluid flow channel that includes a plurality of passes. Such transversal of the entire area of the electrode eliminates stagnant regions and thus provides uniform distribution. The long reactant flow path generates a large pressure drop and flooding of electrolytes in the electrode. Another available flow field plate with multiple serpentines to overcome limitations representing the pressure drop has its own limitation that is decreased rate in the number of flow channels where the number of channels in the inlet side is greater than the number of downstream passages that cause exponential decay in number of flow channels.

[0009] Therefore, there is a need for a plate to overcome the limitations associated with serpentine type flow field with unfavourable pressure drop, ineffective utilization of active sites of electrodes thus reducing the efficiency of a charge - discharge hfe cycle, uneven distribution of electrolyte in the electrodes of a flow type battery.SUMMARY

[0010] In one aspect of the present disclosure, a flow field plate may be provided. The flow field plate may include an inlet port to receive a first electrolyte, a first inlet, a second inlet, a third inlet, a fourth inlet for collecting the first electrolyte from the inlet port, and further adapted to deliver the collected electrolyte to a first quadrant, a second quadrant, a third quadrant, and a fourth quadrant respectively, a drain canal that is adapted to collect a reacted first electrolyte from each quadrant of the first quadrant, the second quadrant, the third quadrant, andthe fourth quadrant and further transfers the collected first electrolyte to an outlet port.BRIEF DESCRIPTION OF DRAWINGS

[0011] The above and further features and advantages of aspects of the present disclosure become apparent upon consideration of the following detailed description of aspects thereof, especially when taken in conjunction with the accompanying drawings— to facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures— and wherein:

[0012] FIG. 1 illustrates a set of plates of a battery pack system, in accordance with an aspect of the present disclosure;

[0013] FIG. 2A illustrates a front view of a flow field plate in the set of plates, in accordance with an aspect of the present disclosure;

[0014] FIG. 2B illustrate a front view of the flow field plate in the set of plates, in accordance with an aspect of the present disclosure;

[0015] FIG. 2C illustrates a magnified view of an inlet corner of the flow field plate, in accordance with an aspect of the present disclosure; and

[0016] FIG. 2D illustrates a magnified view of an outlet corner of the flow field plate, in accordance with an aspect of the present disclosure.DETAILED DESCRIPTION

[0017] Various aspect of the present disclosure provides a split serpentine flow field plate, system, and method. The following description provides specific details of certain aspects of the disclosure illustrated in the drawings to provide a thorough understanding of those aspects. It should be recognized, however, that the present disclosure can be reflected in additional aspects and the disclosure may be practiced without some of the details in the following description.

[0018] The various aspects including the example aspects are now described more fully with reference to the accompanying drawings, in which the various aspects of the disclosure are shown. The disclosure may, however, be embodied in different forms and should not be construed as limited to the aspects set forth herein. Rather, these aspects are provided so that this disclosure is thorough andcomplete, and fully conveys the scope of the disclosure to those skilled in the art. In the drawings, the sizes of components may be exaggerated for clarity.

[0019] It is understood that when an element or layer is referred to as being “on,” “connected to,” or “coupled to” another element or layer, it can be directly on, connected to, or coupled to the other element or layer or intervening elements or layers that may be present. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0020] The subject matter of example aspects, as disclosed herein, is described with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventor / inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different features or combinations of features similar to the ones described in this document, in conjunction with other technologies.

[0021] Generally, the various aspects including the example aspects relate to a split serpentine flow field plate and system. As mentioned, there remains a need for a plate to overcome the limitations associated with serpentine-type flow field with unfavourable pressure drop, ineffective utilization of active sites of electrodes thus reducing the efficiency of a charge-discharge life cycle, uneven distribution of electrolyte on the electrodes of a flow type battery. The present disclosure, therefore, provides a split serpentine flow plate, system, and method that uniformly distributes the electrolyte across the electrodes.

[0022] FIG. 1 illustrates a perspective view of a set of plates 100 of a battery pack system, in accordance with an aspect of the present disclosure. The set of plates 100 may be disposed inside a battery pack system. In some aspects of the present disclosure, the battery pack system may be provided with one or more sets of plates 100. In some aspects of the present disclosure, each set of plates 100 may be adapted to pass anolyte and catholyte respectively.

[0023] The set of plates 100 may include a flow field platel02, a current collector 104, a graphite felt electrode 106, an insulated plate 108, a flow frame 110, a compressible gasket 112, and a polymer membrane 114.

[0024] The flow field plate 102 may include a plurality of channels, wherein eachchannel may facilitate a first electrolyte to circulate on the plurality of channels provided on the flow field plate 102 thereby reacting with the current collector 104. In some aspects of the present disclosure, the flow field plate 102 may be adapted to pass the first electrolytes across the channels provided on the flow field plate 102.

[0025] The current collector 104 may be disposed adjacent to a first side 118 of the flow field platel02. In some aspects of the present disclosure, the current collector 104 enables a flow of electrons from the first electrolyte to an external electrode while discharging.

[0026] In some aspects of the present disclosure, the current collector 104 enables a flow of electrons from the external electrode to the first electrolyte electrode while charging. In some aspects of the present disclosure, the current collector 104 may be a copper current collector.

[0027] The graphite felt electrode 106 may be disposed adjacent to a second side 120 of the flow field platel02. The graphite felt electrode 106 may be adapted to prevent the flow of electrons to the second side 120 of the flow field platel02. Such that the electrons pass only through the current collector 104.

[0028] The insulated plate 108 may be disposed adjacent to the current collector 104. In some aspects of the present disclosure, the insulated plate 108 and the flow field platel02 may sandwich the current collector 104. In some other aspects of the present disclosure, insulated plate 108 may be a non-conducting material. In some aspects of the present disclosure, the insulated plate 108 may be adapted to provide mechanical strength to the set of plates 100. In some aspects of the present disclosure, the insulated plate 108 may be adapted to provide mechanical support to the set of plates 100. The set of plates 100 may further include an end plate 116.

[0029] The end plate 116 may provide mechanical strength and structure to the set of plates 100. In some aspects of the present disclosure, the end plate 116 may be adapted to prevent the set of plates 100 from deformation. In some aspects of the present disclosure, the insulated plate 108 and the end plate 116 may be replaced by a single plate with mechanical strength and non-conductiveproperties.

[0030] The flow frame 110 may be disposed adjacent to the graphite felt electrode 106. In some aspects of the present disclosure, the flow frame 110 and the flow field platel02 may sandwich the graphite felt electrode 106.

[0031] The flow frame 110 may be adapted to restrict the flow of a first electrolyte by providing a sealing effect. In some aspects of the present disclosure, the flow frame 110 may be adapted to bind the flow field plate 102 and the graphite felt electrode 106 together and further may enable the first electrolyte to flow across the flow field plate 102.

[0032] In some aspects of the present disclosure, the flow frame 110 may be a non- porous and non-permeable frame. In some aspects of the present disclosure, the flow frame 110 may be a graphite frame with high electrical conductivity. In some aspects of the present disclosure, the electrical conductivity of the graphite frame may be 104 Siemens per centimetre (s / cm).

[0033] The compressible gasket 112 may be disposed adjacent to the flow frame 110. In some aspects of the present disclosure, the compressible gasket 112 and the graphite felt electrode 106 may sandwich the flow frame 110. In some aspects of the present disclosure, the compressible gasket 112 may be adapted to seal each cell of the set of plates 100. In some aspects of the present disclosure, the compressible gasket 112 may be adapted to compress the graphite felt electrode 106 with the flow frame 110 to achieve optimum performance.

[0034] The polymer membrane 114 may be disposed adjacent to the compressible gasket 112. The polymer membrane 114 may be adapted to prevent cross-mixing of the first electrolyte with a second electrolyte. In some aspects of the present disclosure, the polymer membrane 114 may be adapted to prevent a short circuit of set of plates 100 with a second set of plates of the battery pack system (not shown) during transfer of ions to complete a circuit.

[0035] FIG. 2A illustrates a front view of a flow field plate 102 in the set of plates, in accordance with an aspect of the present disclosure; FIG. 2B illustrates a front view of the flow field plate 102 in the set of plates, in accordance with an aspect of the present disclosure. FIG. 2C illustrates a magnified view of an inlet corner“A” of the flow field plate 102, in accordance with an aspect of the present disclosure.

[0036] FIG. 2D illustrates a magnified view of an outlet corner “B” of the flow field plate 102, in accordance with an aspect of the present disclosure. The flow field plate 102 may include an inlet port 202, a first inlet 204, a second inlet 206, a third inlet 208, a fourth inlet 210, a first quadrant 212, a second quadrant 214, a third quadrant 216, and a fourth quadrant 218, a drain canal 220, an outlet port 222. The inlet port 202 may facilitates flow of the first electrolyte through the inlet port 202.

[0037] In some aspects of the present disclosure, the inlet port 202 may be coupled with an input tube of a first electrolyte tank. The inlet port 202 may further distribute the first electrolytes among the first inlet 204, the second inlet 206, the third inlet 208, and the fourth inlet 210.

[0038] The first inlet 204 may facilitate the flow of the first electrolyte from the inlet port 202 to the first quadrant 212. The second inlet 206 may facilitate the flow of the first electrolyte from the inlet port 202 to the second quadrant 214. The third inlet 208 may facilitate flow of first electrolyte from the inlet port 202 to the third quadrant 216. The fourth inlet 210 may facilitate flow of the first electrolyte from the inlet port 202 to the fourth quadrant 218.

[0039] The first inlet 204 and the third inlet 208 may include a first orifice 234 and a second orifice 236 respectively. The first and second orifices 234 and 236 may be disposed adjacent to a collection point of the first inlet 204 and the third inlet 208 respectively as shown in FIG. 2C. The first orifice 234 and the second orifice 236 may be adapted to restrict in flowrate in the first inlet 204 and the second inlet 206 such that the flow rates in the third inlet 208 and in the fourth inlet 210 are maintained.

[0040] In some aspects of the present disclosure, the second inlet 206 and the fourth inlet 210 may include wide passages respectively, such that the flow rate of the first electrolyte in the second quadrant 214 and the fourth quadrant 218 are maintained concerning the flow rate of the first electrolyte in the first quadrant 212 and the third quadrant 216.

[0041] Each quadrant of the first quadrant 212, the second quadrant 214, the third quadrant 216, and the fourth quadrant 218 may include a serpentine-like flow channel. The serpentine-like flow channels are variable in length with a split in transverse length from inlet to outlet.

[0042] The drain canal 220 may be adapted to collect the first electrolyte from each quadrant of the first quadrant 212, the second quadrant 214, the third quadrant 216, and the fourth quadrant 218. The drain canal 220 may further be adapted to pass the collected first electrolyte to the outlet port 222.

[0043] The outlet port 222 may be coupled with an outlet tube of the first electrolyte tank. The flow field platel02 may further include a first wall rib 224, a second wall rib 226, a third wall rib 228, a fourth wall rib 230, and a fifth wall rib 232.

[0044] The first wall rib 224 may be disposed between the first quadrant 212 and the third quadrant 216. The second wall rib 226 may be disposed between the first quadrant 212 and the second quadrant 214. The third wall rib 228 may be disposed between the third quadrant 216 and the fourth quadrant 218.

[0045] The fourth wall rib 230 and the fifth wall rib 232 may be disposed in a parallel configuration with each other and the parallel configuration is disposed between the second quadrant 214 and the fourth quadrant 218 as shown in FIG. 2D. In some aspects of the present disclosure, the thickness of the fourth wall rib 230 and the fifth wall rib 232 may gradually decrease from the outlet corner as represented by reference numerals 238,240 and 242 of FIG. 2D. In some aspects of the present disclosure, the change in the thickness reduces an unfavourable pressure drop of the first electrolyte. In some aspects of the present disclosure, the thickness of the fourth wall rib 230 and the fifth wall rib 232 may be constant for short channels. In some aspects of the present disclosure, the set of plates 100 may be disposed in the battery pack system (not shown).

[0046] In some aspects of the present disclosure, a method of working of the set of plates 100 may include the following steps: receiving, by way of the inlet port 202, first electrolyte; distributing, by way of the first inlet 204, the second inlet 206, the third inlet 208, and the fourth inlet 210, the received first electrolyte; passing,by way of the first quadrant 212, the second quadrant 214, the third quadrant 216, the fourth quadrant 218, the distributed first electrolyte; and collecting, by way of the drain canal 220, the first electrolyte.

[0047] The foregoing discussion of the present disclosure has been presented for purposes of illustration and description. It is not intended to limit the present disclosure to the form or forms disclosed herein. In the foregoing Detailed Description, for example, various features of the present disclosure are grouped in one or more aspects, configurations, or aspects for the purpose of streamlining the disclosure. The features of the aspects, configurations, or aspects may be combined in alternate aspects, configurations, or aspects other than those discussed above. This device of disclosure is not to be interpreted as reflecting an intention the present disclosure requires more features than are expressly recited in each claim.

[0048] Moreover, though the description of the present disclosure has included description of one or more aspects, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the present disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights that include alternative aspects, configurations, or aspects to the extent permitted, including alternate, interchangeable, and / or equivalent structures, functions, ranges, or steps to those claimed, whether or not such alternate, interchangeable, and / or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.

Claims

CLAIMSWe Claim:

1. A flow field plate 102 comprising: an inlet port 202 configured to receive a first electrolyte; a first inlet 204, a second inlet 206, a third inlet 208, and a fourth inlet 210, each fluidly connected to the inlet port 202, and configured to distribute the first electrolyte to a first quadrant 212, a second quadrant 214, a third quadrant 216, and a fourth quadrant 218, respectively; a drain canal 220 configured to collect a reacted first electrolyte from each of the a first quadrant 212, a second quadrant 214, a third quadrant 216 and a fourth quadrant 218; and an outlet port 222 fluidly connected to the drain canal 220, and configured to discharge the reacted first electrolyte.

2. The flow field plate of claim 1, wherein each of the first quadrant 212, a second quadrant 214, a third quadrant 216, and a fourth quadrant 218 comprise a serpentine flow channel.

3. The flow field plate of claim 2, wherein the serpentine flow channels are variable in length with a split in transverse length from inlet to outlet.

4. The flow field plate of claim 1, wherein the first inlet 204 and the third inlet 208 each comprise an orifice 234, 236 configured to restrict flow rate.10SUBSTITUTE SHEET RULE 265. The flow field plate of claim 1, wherein the second inlet 206 and the fourth inlet 210 comprise widened passages configured to maintain a flow rate of the first electrolyte.

6. The flow field plate of claim 1, further comprising: a first wall rib 224 disposed between the first quadrant and the third quadrant; a second wall 226 rib disposed between the first quadrant and the second quadrant; a third wall rib 228 disposed between the third quadrant and the fourth quadrant; a fourth wall rib 230; and a fifth wall rib 232; wherein the fourth wall rib 230 and the fifth wall rib 232 are disposed in a parallel configuration between the second quadrant 214 and the fourth quadrant 218.

7. The flow field plate of claim 6, wherein a thickness of the fourth wall rib 230 and the fifth wall rib 232 gradually decreases from the outlet port.

8. A flow battery system comprising: a flow field plate 102 according to claim 1; a current collector 104 disposed adjacent to a first side 118 of the flow field plate 102 ; a graphite felt electrode 106 disposed adjacent to a second side 120 of the flow field plate 102;1 1SUBSTITUTE SHEET RULE 26a polymer membrane 114; and a flow frame 110.

9. The flow battery system of claim 8, further comprising: an insulated plate disposed adjacent to the current collector; and a compressible gasket disposed adjacent to the graphite felt electrode.

10. A method of operating a flow battery system, comprising: receiving a first electrolyte at an inlet port of a flow field plate; distributing the first electrolyte from the inlet port to a first quadrant, a second quadrant, a third quadrant, and a fourth quadrant of the flow field plate via a first inlet, a second inlet, a third inlet, and a fourth inlet, respectively; flowing the first electrolyte through serpentine flow channels within each of the first quadrant, the second quadrant, the third quadrant, and the fourth quadrant; collecting a reacted first electrolyte from each of the first quadrant, the second quadrant, the third quadrant, and the fourth quadrant at a drain canal of the flow field plate; and discharging the reacted first electrolyte from the drain canal through an outlet port of the flow field plate.12SUBSTITUTE SHEET RULE 2611. A set of plates 100 for a battery pack system, the battery pack system comprising: a flow field plate 102 with a plurality of channels to facihtate the circulation of a first electrolyte; a current collector 104 disposed adjacent to a first side 118 of the flow field plate 102, enabling the flow of electrons from the first electrolyte to an external electrode while discharging and enabling flow of electrons to the first electrolyte to an external electrode while charging; a graphite felt electrode 106 disposed adjacent to a second side 120 of the flow field plate 102, adapted to prevent electron flow to the second side, such that electrons pass only through the current collector 104 wherein the graphite felt electrode 106 enables the first electrolyte to flow across the flow field plate 102, being a non-porous and non-permeable frame having electrical conductivity of magnitude 104microsiemens per centimetre (ps / cm); an insulated plate 108 disposed adjacent to the current collector 104 to provide mechanical strength and support to the set of plates 100; a flow frame 110 disposed adjacent to the graphite felt electrode 106, the flow frame 110 adapted to restrict the flow of the first electrolyte by providing a sealing effect and bind flow field in the flow field plate 102; a compressible gasket 112 disposed adjacent to the flow frame 110, seal each cell of the set of plates 100 and compress the graphite felt electrode 106 with the flow frame 110 for performance; and a polymer membrane 114 disposed adjacent to the compressible gasket 112 to prevent cross-mixing of the first13SUBSTITUTE SHEET RULE 26electrolyte with a second electrolyte and prevent a short circuit with the set of plates 100 during transfer of ions to complete a circuit for the flow of current.

12. The set of plates 100 of for a battery pack system of claim 11, wherein the flow field plate 102 includes an inlet port 202 coupled with an input tube of a first electrolyte tank, the inlet port 202 is connected with a first inlet 204, wherein the first inlet 204 facilitates the flow of the first electrolyte from the inlet port 202 to a first quadrant 212, a second inlet 206 wherein the first second inlet 204 facilitates the flow of the first electrolyte from the inlet port 202 to a second quadrant 214, a third inlet 208 wherein the third inlet 208 facilitates the flow of the first electrolyte from the inlet port 202 to a third quadrant 216 and a fourth inlet 210 wherein the fourth inlet 210 facilitates flow of the first electrolyte from the inlet port 202 to the fourth quadrant 218, to distribute the first electrolyte across the flow field 102.

13. The set of plates 100 of for a battery pack system of claim 2, wherein the first inlet 204 and the third inlet 208 include a first orifice 234 and a second orifice 236 respectively, which are disposed adjacent to a collection point of the first inlet 204 and the third inlet 208 respectively, wherein the first orifice 234 and the second orifice 236 restrict in flowrate in the first inlet 204 and the second inlet 206 such that14SUBSTITUTE SHEET RULE 26the flow rates in the third inlet 208 and in the fourth inlet 210 are maintained.

14. The set of plates 100 of for a battery pack system of claim 3, wherein the second inlet 206 and the fourth inlet 210 have passages such that the flow rate of the first electrolyte in the second quadrant 214 and the fourth quadrant 218 are maintained with respect to the flow rate of the first electrolyte in the first quadrant 212 and the third quadrant 216, wherein each of the first quadrant 212, the second quadrant 214, the third quadrant 216, and the fourth quadrant 218 include a serpentine-like flow channel being variable in length with a split in transverse length from inlet to outlet.

15. The set of plates 100 of for a battery pack system of claim 4, further comprising: the flow field 102 having a drain canal 220 to collect the first electrolyte from each of the first quadrant 212, the second quadrant 214, the third quadrant 216, and the fourth quadrant 218, and pass the collected first electrolyte to the outlet port 222.

16. The set of plates 100 of for a battery pack system of claim 15: wherein the flow field platel02 further includes a first wall rib 224, a second wall rib 226, a third wall rib 228, a fourth wall rib 230, and a fifth wall rib 232 to separate the quadrants, wherein the first wall rib 224 separates the first quadrant 212 and the third quadrant 216, the second wall rib 226 separates the first quadrant 212 and the second quadrant 214,15SUBSTITUTE SHEET RULE 26the third wall rib 228 separates the third quadrant 216 and the fourth quadrant 218, and the fourth wall rib 230 and the fifth wall rib 232 are in a parallel configuration with each other and the parallel configuration is disposed between the second quadrant 214 and the fourth quadrant 218, wherein the thickness of the fourth wall rib 230 and the fifth wall rib 232 gradually decreases from the outlet corner and the change in the thickness reduces pressure drop of the first electrolyte, the thickness of the fourth wall rib 230 and the fifth wall rib 232 is constant for short channels.

17. A method of operating a set of plates 100 for a battery pack system of claim 11: comprising: receiving a first electrolyte through the inlet port 202; distributing the first electrolyte through the first inlet 204, the second inlet 206, the third inlet 208, and the fourth inlet 210 across the flow field plate 102; passing the distributed first electrolyte through the first quadrant 212, the second quadrant 214, the third quadrant 216, and the fourth quadrant 218 of the flow field plate 102: and collecting the first electrolyte via a drain canal 220 and directing it to the outlet port 222.* * *16SUBSTITUTE SHEET RULE 26

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