Alkaline Battery Electrode Height Ratio and Density Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Alkaline batteries with reduced positive and negative electrode filling densities face issues with internal short circuits due to gel leakage, particularly when the negative electrode's filling density is lowered, leading to reduced reaction efficiency and increased heat generation upon impact.
Innovation Solution
The alkaline battery design sets a specific ratio between the heights of the positive and negative electrodes within a range of 0.96 to 1.06, combined with optimized filling densities for manganese dioxide (2.31 to 2.45 g/cm³) and zinc (1.49 to 1.65 g/cm³), to minimize gel leakage and maintain high reliability and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the filling density of the negative electrode is reduced to lower cost, then the cost decreases, but the gel negative electrode becomes less viscous and more likely to leak upon impact, causing internal short circuits
Solution Approach 1:
The patent applies parameter changes by optimizing the filling density of the negative electrode to a specific range (1.49 to 1.65 g/cm³) that balances cost reduction with maintaining sufficient gel viscosity to prevent leakage and internal short circuits upon impact
Solution Approach 2:
The patent uses composite materials by formulating the negative electrode as a gel system containing zinc particles suspended in an alkaline electrolyte gel, where the gel matrix provides structural integrity and prevents leakage while maintaining electrical functionality
2Ease of manufacture
If the filling densities of positive and negative electrodes are reduced to improve cost performance, then the cost performance improves, but the reaction efficiency deteriorates due to decreased electrode opposition area
Solution Approach 1:
The patent applies parameter changes by optimizing multiple parameters simultaneously: negative electrode filling density (1.49 to 1.65 g/cm³), positive electrode filling density (2.31 to 2.45 g/cm³), and the height ratio between electrodes (0.96 to 1.06), achieving a balance between cost performance and reaction efficiency
3Ease of manufacture
If the filling density of the positive electrode is reduced to lower cost, then the cost decreases, but the electrode structure becomes less stable and may contribute to internal short circuits
Solution Approach 1:
The patent applies parameter changes by setting the positive electrode filling density within the optimized range of 2.31 to 2.45 g/cm³, which maintains sufficient structural stability to prevent electrode deformation and internal short circuits while achieving cost reduction
Data Source
Figure 1A~1D
Figure 2
AI summary
The present invention provides an alkaline battery which has high reliability and high cost performance and does not cause an internal short circuit resulting from gel leakage even when the filling densities of the positive and negative electrodes are reduced. In the alkaline battery, a positive electrode 2 contains manganese dioxide as a positive electrode active material, a negative electrode 3 is a gel negative electrode containing zinc as a negative electrode active material, a filling density of manganese dioxide in the positive electrode 2 is in a range of 2.31 to 2.45 g/cm3, a filling density of zinc in the negative electrode 3 is in a range of 1.49 to 1.65 g/cm3, and a ratio (h1/h2) between a height of the positive electrode 2 (h1) and a height of the negative electrode 3 (h2) is in a range of 0.96 to 1.06.