Mechanically Actuated Valve Controls Battery Electrolyte Entry

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Solution Overview

Problem

Sealed batteries face undesirable shelf life due to premature activation, and dry charged batteries require inefficient procedures for forming battery plates, leading to electrolyte spills and extended lead time for operation.

Innovation Solution

A battery with a mechanically actuated valve for controlled electrolyte entry, a fixture for forming battery plates with a housing and partitions, and a method involving a conditioning charge to activate the plates, which reduces maintenance and manufacturing time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If sealed batteries are filled with electrolyte upon manufacture, then the battery is ready for immediate use, but the battery suffers from premature activation and reduced shelf life

Engineering Contradiction:

Improvebattery readinessVSAvoidshelf life

Core Design Contradiction:

Ease of operationVSDuration of action of stationary object

Solution Approach 1:

The battery system is segmented into two independent parts: the battery assembly (housing, plates, valve) and the electrolyte container. This segmentation allows the battery to be manufactured and stored without electrolyte, extending shelf life, while enabling quick activation by simply connecting the electrolyte container, thus maintaining ease of operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The battery plates are pre-formed and the battery assembly is pre-assembled with all components except the electrolyte. The mechanically actuated valve is pre-installed and configured to control electrolyte entry. This preliminary preparation allows the battery to be ready for immediate activation without requiring complex assembly procedures at the point of use.

Inventive Principle:

Principle #10Preliminary action

2Duration of action of stationary object

If dry charged batteries are used to extend shelf life, then the battery maintains longer storage capability, but inefficient plate forming procedures lead to electrolyte spills and extended lead time

Engineering Contradiction:

Improveshelf lifeVSAvoidactivation speed

Core Design Contradiction:

Duration of action of stationary objectVSProductivity

Solution Approach 1:

The traditional manual or complex mechanical plate forming procedures are replaced with an electrochemical conditioning charge process. The battery plates are formed in-situ within the battery assembly using electrical current, eliminating the need for separate mechanical forming operations that cause spills and delays. This substitution dramatically reduces activation time while maintaining shelf life benefits.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The battery system performs its own plate forming operation internally through the conditioning charge process. The electrolyte, once introduced, serves dual purposes: as the operating medium and as the medium for forming the battery plates. This self-service approach eliminates the need for separate external forming procedures, reducing both time and spill risks.

Inventive Principle:

Principle #25Self-service

3Loss of substance

If a mechanically actuated valve is added to control electrolyte entry, then electrolyte loss is limited, but the device complexity increases

Engineering Contradiction:

Improveelectrolyte lossVSAvoidvalve mechanism

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The electrolyte is extracted from the main battery housing and placed in a separate container with a controlled delivery system. The mechanically actuated valve is located in the electrolyte container rather than the battery housing, simplifying the overall system architecture. This extraction approach allows the valve to control electrolyte flow at the source, minimizing loss while keeping the battery housing simple.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanically actuated valve serves as an intermediary component between the electrolyte container and the battery assembly. It provides a controlled interface for electrolyte transfer, enabling precise control of electrolyte entry while isolating the complexity of the valve mechanism from the battery housing design. The valve acts as a mediator that manages the interface between the two segmented parts.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables efficient filling of batteries, limits electrolyte loss, and facilitates the use of thinner battery plates, improving battery readiness and reducing maintenance needs.

Implementation Method 1

providing a conditioning charge to a battery plate disposed in a fixture comprising an electrolyte

Methodology Applied

Scientific EffectElectrochemical reaction: Electrolysis

Data Source

PatentUS11271276B2Battery, a fixture for forming a battery plate, a kit, and a related method of manufacture

Publication Date: 2022.03.08 TELEDYNE TECHNOLOGIES INC

AI summary

A battery, a fixture for forming a battery plate, a kit, and a related method of manufacture are provided. The battery comprises a housing and a mechanically actuated valve. The housing defines a cell configured to receive battery plates. The mechanically actuated valve is in fluid communication with the cell and configured to control entry of electrolyte into the cell.