Battery Cell Monolith for Hydrogen Sulfide Gas Mitigation

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Solution Overview

Problem

Lithium-sulfur batteries face performance and longevity issues due to the formation of hydrogen sulfide gas when exposed to moisture, which interacts with the sulfide-based solid-state electrolyte or sulfur cathode.

Innovation Solution

Incorporation of a monolith with catalyst materials like Ni/Ce, Cu/Zeolite, or Fe/Zeolite within the battery cell to hydrolyze hydrogen sulfide gas into sulfur dioxide and water, releasing the byproducts externally through channels configured for direct or porous wall flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If lithium-sulfur batteries use sulfide-based solid-state electrolyte or sulfur cathode, then theoretical specific energy is improved, but hydrogen sulfide gas is generated when exposed to moisture

Engineering Contradiction:

Improvetheoretical specific energyVSAvoidhydrogen sulfide gas generation

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The patent applies the 'Blessing in disguise' principle by converting the harmful H2S gas into beneficial products. The catalytic converter transforms H2S into sulfur (useful for the battery cathode) and hydrogen (useful for the battery anode), thereby converting a harmful byproduct into valuable materials that can be reused in the battery system.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent employs an intermediary approach by introducing a catalytic converter as a mediator between the battery components and the external environment. This intermediary device captures and processes H2S gas before it can cause harm, using catalysts to facilitate the conversion of H2S into useful substances.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If hydrogen sulfide gas is released from battery cells, then moisture exposure reaction occurs, but battery performance and longevity are reduced

Engineering Contradiction:

Improvehydrogen sulfide gas releaseVSAvoidbattery performance and longevity

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The catalytic converter transforms the harmful H2S gas into beneficial products - sulfur that can be used in the cathode and hydrogen that can be used in the anode. This conversion not only eliminates the harmful effects but also recovers valuable materials, thereby improving battery performance and longevity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent applies the 'Discarding and recovering' principle by capturing H2S gas that would otherwise be discarded and converting it into recoverable valuable materials - sulfur and hydrogen. This recovery process prevents material loss and maintains battery performance over time.

Inventive Principle:

Principle #34Discarding and recovering

3Object-generated harmful factors

If a monolith with catalyst materials is incorporated to hydrolyze hydrogen sulfide gas, then hydrogen sulfide mitigation is improved, but device complexity increases

Engineering Contradiction:

Improvehydrogen sulfide gas mitigationVSAvoidbattery cell structure

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The catalytic converter serves multiple functions: it acts as a structural support, provides catalytic surfaces for H2S conversion, and functions as a gas processing unit. By combining these functions into a single monolithic component, the patent reduces overall system complexity while achieving effective H2S mitigation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses a porous monolith structure that provides high surface area for catalytic reactions while maintaining a compact form factor. The porous structure allows gas flow through the material and provides numerous active sites for H2S conversion, achieving effective mitigation without significantly increasing device complexity.

Inventive Principle:

Principle #31Porous materials

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

Effectively mitigates hydrogen sulfide gas, preserving battery cell integrity and extending lifespan by converting H2S to less harmful sulfur dioxide and water, enhancing battery performance and reliability.

Implementation Method 1

The monolith may include catalyst material. The monolith may include a plurality of channels coated with the catalyst material extending therethrough. The catalyst material may be Ni/Ce, Cu/Zeolite, and Fe/Zeolite individually or in combination.

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

a monolith configured to hydrolyze hydrogen sulfide gas, precipitated from moisture exposure to the cathode, into sulfur dioxide and water

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Data Source

PatentUS20250309386A1Gas mitigation for battery systems

Publication Date: 2025.10.02 FORD GLOBAL TECH LLC

AI summary

This disclosure relates to systems and methods for hydrogen sulfide mitigation. A battery cell or plurality of battery cells in a battery pack with a sulfur-containing lithium-based rechargeable battery component is presented. A monolith hydrolyzes hydrogen sulfide gas, precipitated from moisture exposure to the sulfur-based cathode, into sulfur dioxide and water, and releases the sulfur dioxide and water external to the battery cell.