Battery Housing Corrosion Resistance via Composite Laminate
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Solution Overview
Problem
Existing battery housings made of non-reactive metals are susceptible to galvanic or electrolytic corrosion when condensation occurs between the case and cap, leading to potential battery failure and pack failure.
Innovation Solution
A battery housing design utilizing a composite structure with layers of α-glucan and chitin fibers, including cellulosic fibers, and a manufacturing method involving mycelium growth and curing, which forms a corrosion-resistant laminate for the case and cap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-reactive metals are used for case and cap, then the housing is non-reactive to the cell and electrolyte, but galvanic or electrolytic corrosion occurs when condensation accumulates at the interface
Solution Approach 1:
The patent applies composite materials by using a laminate structure consisting of multiple layers including aluminum foil layers, polymer layers, and metal oxide layers. This composite structure combines the non-reactivity of aluminum with protective properties of polymer and metal oxide layers, preventing galvanic and electrolytic corrosion while maintaining non-reactivity to the cell and electrolyte. The multi-layer composite effectively addresses the corrosion issue that plagues single-material metallic housings.
Solution Approach 2:
The patent changes the material parameters by transitioning from pure metallic materials to a composite laminate with specific layer compositions and thicknesses. The aluminum foil layers are combined with polymer layers (such as polyethylene or polypropylene) and metal oxide layers (such as aluminum oxide or aluminum hydroxide) in controlled thicknesses to optimize both non-reactivity and corrosion resistance. This parameter change allows the housing to resist both chemical reactions with electrolyte and electrochemical corrosion.
2Strength
If metallic materials are used for case and cap, then structural strength is achieved, but susceptibility to corrosion increases under condensation conditions
Solution Approach 1:
The patent employs composite materials to simultaneously achieve structural strength and corrosion resistance. The laminate structure includes aluminum foil layers that provide structural strength and rigidity, while the polymer layers (polyethylene or polypropylene) and metal oxide layers (aluminum oxide or aluminum hydroxide) provide corrosion resistance. This composite approach allows the housing to maintain mechanical integrity while being immune to galvanic and electrolytic corrosion that affects pure metallic housings.
Solution Approach 2:
The patent applies local quality by assigning different functions to different layers of the laminate. The aluminum foil layers are positioned to provide structural strength and barrier properties, while the polymer layers provide corrosion protection and flexibility, and the metal oxide layers provide additional corrosion resistance and chemical stability. Each layer is optimized for its specific function, allowing the overall structure to achieve both strength and corrosion resistance.
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 solution minimizes the occurrence of electrolytic and galvanic corrosion, thereby increasing battery longevity and pack life by using materials that do not undergo redox reactions under normal conditions.
Implementation Method 1
growing mycelium for a period of one to twenty days while exposed to a magnetic field to produce a first layer comprising a first three-dimensional network of fibers
Implementation Method 2
growing mycelium for a period of one to twenty days while exposed to a magnetic field to produce a first layer comprising a first three-dimensional network of fibers
Implementation Method 3
curing the first layer comprising the first three-dimensional network of fibers at a temperature of at least one hundred and fifty degrees Fahrenheit to terminate growth of the first layer
Implementation Method 4
placing the first laminate in a first mold, the first mold having the shape of a case, and exposing the first laminate to a vacuum and a pressure to form the case
Data Source
AI summary
A cell housing is disclosed. The cell housing may include a case extending between a first side, a second side, an open top end and an integrated bottom end. The cell housing may additionally include a body extending between an inner surface and an outer surface and the body may include a first layer comprising a first three-dimensional network of fibers including α-glucan and chitin, a second layer comprising a second three-dimensional network of fibers including α-glucan and chitin and include a plurality of cellulosic fibers positioned between the first layer and the second layer.