Air Cell Outer Frame Integration for Mechanical Strength
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Solution Overview
Problem
Conventional air cells for vehicle power supplies have a complex structure, low mechanical strength of positive electrodes, and compromised sealing performance when stacked, making them unsuitable for vehicles due to stress concentration and potential leakage of electrolysis solutions.
Innovation Solution
The air cell design integrates a positive electrode with an outer frame member for enhanced mechanical strength and sealing, using a resin-based frame with fiber reinforcement and a water-repellent layer to prevent electrolysis solution leakage, allowing for a simpler, thinner structure that can be stacked without wires, with the frame members made of materials like polypropylene or engineering plastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the air cell structure is simplified and thickness is reduced, then the air cell becomes suitable for vehicle mounting with smaller space requirements, but the positive electrodes bend and mechanical strength decreases
Solution Approach 1:
The patent applies composite materials by combining the positive electrode with a reinforcing layer made of different material properties. The reinforcing layer provides mechanical strength to prevent bending while maintaining the thin overall structure needed for vehicle mounting. This composite construction allows the thin positive electrode to gain structural support without increasing thickness significantly.
Solution Approach 2:
The patent uses thin film structures for the positive electrode while incorporating a reinforcing layer that acts as a flexible shell providing structural support. This allows the electrode to remain thin for space efficiency while the reinforcing layer prevents bending and maintains mechanical integrity during stacking and operation.
2Reliability
If the positive electrodes push rubber gaskets to maintain sealing performance, then sealing is improved, but deformation of positive electrodes occurs and sealing performance reduces
Solution Approach 1:
The patent introduces a sealing member as an intermediary element between the positive electrode and the battery case. This sealing member performs the sealing function without requiring the positive electrode to deform or push rubber gaskets. The sealing member is specifically designed to maintain contact and sealing performance while allowing the positive electrode to maintain its shape and structural stability.
Solution Approach 2:
The patent extracts the sealing function from the positive electrode structure itself and assigns it to a separate sealing member. This separation allows the positive electrode to focus on its electrochemical function without being compromised by sealing requirements, while the dedicated sealing member handles the sealing task effectively.
3Strength
If conventional air cells with complex structures are used, then sealing and mechanical strength are maintained, but the number of parts increases and assembly becomes complicated
Solution Approach 1:
The patent merges multiple functions into integrated components. The positive electrode is combined with the reinforcing layer as a single integrated structure, eliminating the need for separate support elements. The sealing member is integrated into the battery case structure, reducing the number of discrete parts. This merging maintains mechanical strength and sealing performance while simplifying the overall structure and reducing part count.
Solution Approach 2:
The patent designs components with multiple functions. The battery case structure serves both as the container and as part of the sealing system through the integrated sealing member. The reinforcing layer both strengthens the positive electrode and provides structural support for the overall cell assembly. This multi-functionality reduces the need for dedicated separate components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration increases the mechanical strength and sealing performance of the air cell, enabling a reduction in thickness while maintaining high output performance and preventing electrolysis solution leakage, even when stacked, making it suitable for vehicle-mounted batteries.
Implementation Method 1
a water-repellent layer which prevents penetration of an electrolysis solution
Data Source
Figure 1~2(c)
Figure 3~4
Figure 5(a)~5(e)
AI summary
An air cell (10) includes a positive electrode (1) and a negative electrode (2), and an outer frame member (31, 32) located at outer peripheries of the positive electrode (1) and the negative electrode (2). The positive electrode (1) and the outer frame member are integrally joined together. An assembled battery (100) includes a plurality of air cells, the air cells being stacked on top of each other. This configuration can increase mechanical strength and improve sealing performance for an electrolysis solution in the positive electrode (1). In addition, a reduction in thickness of the entire air cell can be achieved so that the assembled battery suitable for use in a vehicle can be provided.