Bipolar Battery Trough Layout for Electrolyte Flow and Thermal Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Bipolar battery assemblies face challenges with liquid electrolyte leakage, prolonged pickling times, excessive heat generation, and inefficient temperature control during formation, charging, and discharging, leading to issues like swelling, pressure buildup, and mechanical distortion.
Innovation Solution
Incorporation of troughs and channels within the battery assembly to facilitate faster electrolyte distribution, evacuation, and thermal control, allowing for temperature management and reducing the need for curing ovens, while maintaining a seal and using liquid electrolyte.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid electrolyte is used instead of solid electrolyte, then manufacturing cost is reduced and lifespan is extended, but electrolyte leakage occurs and pickling time increases
Solution Approach 1:
The battery assembly is divided into multiple electrochemical cells, each with its own separator and electrolyte containment structure. The separator is segmented into a porous portion and a non-porous portion, creating distinct functional zones that control electrolyte distribution and prevent leakage while maintaining efficient pickling.
Solution Approach 2:
The non-porous portion of the separator acts as an intermediary barrier between the porous electrolyte-containing portion and the external environment. This intermediary structure prevents electrolyte leakage while still allowing the liquid electrolyte to be used, resolving the contradiction between using liquid electrolyte and preventing leakage.
2Ease of manufacture
If liquid electrolyte is used instead of solid electrolyte, then manufacturing cost is reduced and lifespan is extended, but electrolyte leakage occurs
Solution Approach 1:
The separator is segmented into porous and non-porous portions, creating distinct functional zones. The non-porous portion specifically addresses leakage prevention while the porous portion maintains electrolyte contact, allowing liquid electrolyte use without leakage.
Solution Approach 2:
Different portions of the separator have different properties: the porous portion allows electrolyte penetration and contact, while the non-porous portion provides leakage prevention. This local differentiation of properties resolves the contradiction between using liquid electrolyte and preventing leakage.
3Manufacturing precision
If traditional curing and drying processes are used, then active material is properly prepared, but facility space increases and assembly time increases
Solution Approach 1:
The curing and drying processes are merged into a single integrated process that occurs within the battery assembly structure itself. The separator's porous and non-porous portions work together to perform both functions simultaneously, eliminating the need for separate curing ovens and drying facilities.
Solution Approach 2:
The battery assembly structure itself provides the curing and drying functions through its integrated separator design. The porous portion allows for moisture evacuation while the non-porous portion maintains structural integrity, enabling the system to self-service without external curing equipment.
4Productivity
If exothermic pickling and formation processes occur, then battery is activated, but excessive heat is generated causing swelling and mechanical distortion
Solution Approach 1:
The exothermic heat generated during pickling and formation is converted into a beneficial effect by using it to drive the evacuation of moisture through the porous separator. The same thermal energy that causes harmful swelling is redirected to perform useful moisture removal, resolving the contradiction between activation and heat management.
Solution Approach 2:
The process utilizes phase transitions of moisture (from liquid to vapor) during the exothermic pickling and formation processes. The heat generated drives the evaporation and evacuation of moisture through the porous separator, converting potentially harmful thermal energy into a useful drying mechanism.
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
Enhances electrolyte distribution and temperature control, reducing assembly time, preventing mechanical distortion, and improving safety by managing heat, thus enabling faster and more efficient battery preparation processes.
Implementation Method 1
the electrolyte wicks through the pores or paths of the separator to fill the electrochemical cell and be absorbed by the active material
Implementation Method 2
one or more troughs formed in each of the one or more electrochemical cells and adapted to guide flow of electrolyte into the one or more electrochemical cells
Implementation Method 3
The pickling process is usually an exothermic process causing the internal battery temperature to become elevated
Implementation Method 4
Excess heat may also occur as a result of power dissipation as current flows through the internal resistance of the battery during charging or discharging (also known as Joule heating)
Implementation Method 5
The formation process, while endothermic, generates more acid. This generated acid generally continues the pickling process, causing subsequent exothermic reactions
Data Source
AI summary
The present disclosure relates to a bipolar battery comprising one or more troughs formed therein and cooperating with one or more channels, the troughs adapted to guide flow of electrolyte to provide for faster and more uniform flow of the electrolyte. The disclosure relates to a bipolar battery assembly comprising: a) a plurality of electrode plates stacked together to form an electrode plate stack; b) one or more electrochemical cells, wherein each electrochemical cell is formed between a pair of electrode plates; c) one or more separators disposed within the one or more electrochemical cells; and d) one or more troughs formed in each of the one or more electrochemical cells and adapted to guide flow of electrolyte into the one or more electrochemical cells. The present disclosure further relates to a method for preparing a battery assembly. The method may utilize circulating one or more fluids through the battery assembly during preparation. Circulating fluids may be part of thermal control cycling.