Alkaline Battery Pellet Gaps for Heavy Load Discharge

Solution Overview

Problem

Existing alkaline batteries face challenges in improving heavy load discharge performance due to fine powders with small grain diameters, which increase electrical resistance by holding electrolyte on the negative electrode side, reducing its availability on the positive electrode side.

Innovation Solution

An alkaline battery design featuring a tubular positive electrode with stacked pellets and a specific gap ratio, a negative electrode mixture containing zinc alloy powder with particles of 75 μm or less in 25-40% mass, and a positive electrode mixture with manganese dioxide and graphite, optimized for improved discharge performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fine powders with small grain diameter are used as negative electrode material, then heavy load discharge characteristics are improved, but electrolyte is held on the negative electrode side reducing availability on the positive electrode side

Engineering Contradiction:

Improveheavy load discharge characteristicsVSAvoidelectrolyte availability on positive electrode side

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The positive electrode mixture is divided into multiple tubular pellets stacked coaxially within the positive electrode can, creating segmented structures that facilitate electrolyte distribution and improve heavy load discharge performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Gaps are strategically disposed between the tubular pellets at specific positions to create localized regions for electrolyte distribution, ensuring optimal electrolyte availability where needed most for heavy load discharge

Inventive Principle:

Principle #3Local quality

2Reliability

If fine powders with small grain diameter are used as negative electrode material, then heavy load discharge characteristics are improved, but electrical resistance on the positive electrode side increases

Engineering Contradiction:

Improveheavy load discharge characteristicsVSAvoidelectrical resistance on positive electrode side

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The positive electrode mixture is divided into multiple tubular pellets stacked coaxially within the positive electrode can, creating segmented structures that facilitate electrolyte distribution and improve heavy load discharge performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Gaps are strategically disposed between the tubular pellets at specific positions to create localized regions for electrolyte distribution, ensuring optimal electrolyte availability where needed most for heavy load discharge

Inventive Principle:

Principle #3Local quality

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

The design enhances discharge performance, particularly under heavy load conditions, by balancing electrolyte distribution and electrical resistance, achieving superior discharge characteristics.

Implementation Method 1

fine powders having a small grain diameter has a large specific surface, and thus the electrolyte is likely to be held on the negative electrode side

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

an alkaline battery including a positive electrode mixture filling a tubular positive electrode can, a separator disposed on an inner peripheral side of the positive electrode mixture, a negative electrode mixture filling an inner peripheral side of the separator

Methodology Applied

Scientific EffectElectrochemical reaction: Redox Reactions

Data Source

PatentUS11387496B2Method of making alkaline battery with gap between pellets

Publication Date: 2022.07.12 FDK CORP

AI summary

An alkaline battery is made by press-fitting a plurality of tubular positive electrode pellets inside of an open end of a cylindrical positive electrode can. The press-fitting is performed in such a manner as to stack the positive electrode pellets coaxially inside of and in contact with the positive electrode can, with gaps between adjacent positive electrode pellets. A separator is disposed inside of the tubular pellets, and a negative electrode mixture is placed inside of the separator. A negative electrode current collector is inserted into the negative electrode mixture, and the opening at the open end of the positive electrode can is sealed with a negative electrode terminal plate.