Alkaline Battery Sealing Plate with Porous Electrolyte Filter
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Solution Overview
Problem
Existing alkaline batteries face issues with electrolyte leakage when the explosion-proof valve is actuated, as the shielding filter or porous member can rupture or allow a mixture of gas and electrolyte to escape as mist, leading to corrosion and other problems.
Innovation Solution
An alkaline battery design featuring a sealing plate with a gasket and an electrolyte filter made of a porous membrane, where the volume of the space defined by the sealing plate and the electrolyte filter is greater than or equal to 0.25 cm³, and the tensile stress of the electrolyte filter at 100% tensile elongation is in the range of 60-4000 N/m, preventing the electrolyte from leaking by using surface tension to block liquid passage while allowing gas to pass through.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shielding filter or porous member is disposed to reduce electrolyte scattering, then electrolyte leakage is reduced, but the filter may be ruptured under sudden gas pressure or allow gas-electrolyte mixture to escape as mist
Solution Approach 1:
The sealing structure is divided into multiple functional layers: the gasket with explosion-proof valve for pressure relief, and the electrolyte filter made of porous membrane for selective filtration. This segmentation allows each component to specialize - the gasket handles mechanical sealing and pressure release, while the porous membrane handles electrolyte filtration without bearing the full rupture load
Solution Approach 2:
The electrolyte filter made of porous membrane acts as an intermediary between the battery interior and exterior. It selectively allows gas to pass through while blocking electrolyte, serving as a mediator that prevents direct contact between the explosion-proof valve and the external environment, thereby preventing electrolyte leakage without requiring the filter to withstand full rupture pressures
2Speed
If the explosion-proof valve is designed to release gas at high pressure, then gas release is effective, but electrolyte may leak or scatter simultaneously
Solution Approach 1:
The electrolyte filter is made of a porous membrane that allows gas molecules to pass through while blocking larger electrolyte molecules. This porous structure enables rapid gas release during explosion-proof valve actuation while simultaneously preventing electrolyte scattering, resolving the contradiction between gas release speed and electrolyte containment
Solution Approach 2:
The sealing plate has different structural properties in different regions: the vent area allows gas passage, while the area with the electrolyte filter provides selective filtration. This local differentiation of properties allows the sealing structure to simultaneously achieve rapid gas release and electrolyte prevention in different zones
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 design effectively prevents electrolyte leakage when the explosion-proof valve is activated, ensuring the battery's safety and integrity by utilizing the electrolyte filter's buffer space and tensile properties to maintain hermeticity.
Implementation Method 1
preventing the electrolyte from leaking by using surface tension to block liquid passage while allowing gas to pass through
Data Source
AI summary
In an alkaline battery in which an opening of a battery case 1 containing a power-generating element is sealed via a sealing plate 7 with a gasket 5 interposed between the battery case 1 and the sealing plate 7, the sealing plate 7 has a vent 7a, the gasket 5 has an explosion-proof valve 5a, an electrolyte filter 9 made of a porous membrane is disposed in a space defined by the sealing plate 7 and the gasket 5, a volume of a space defined by the sealing plate 7 and the electrolyte filter 9 is greater than or equal to 0.25 cm3, and a tensile stress of the electrolyte filter 9 at 100% tensile elongation in at least one direction is in a range of 60-4000 N/m.