Bridgeless CPV Superstack Layout for Lower-Cost Nickel-Hydrogen Batteries

Solution Overview

Problem

The high cost and complexity of metal-hydrogen batteries are largely due to the cost of the vessel that houses the battery and additional connectors, necessitating a configuration with fewer parts to reduce manufacturing costs and simplify production.

Innovation Solution

A bridgeless Common Pressure Vessel (CPV) superstack configuration for metal-hydrogen batteries, comprising a pressure vessel enclosing a bridgeless CPV superstack with alternating anode-cathode layers, end anodes and cathodes, and electrolyte, eliminating inter-stack bridge connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional metal-hydrogen battery configurations with multiple connectors and bridge components are used, then electrical connectivity between stacks is achieved, but manufacturing cost and device complexity increase significantly

Engineering Contradiction:

Improveelectrical connectivityVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the electrical connection function directly into the pressure vessel structure by making the pressure vessel itself conductive. This eliminates the need for separate bridge connectors and intermediate stacks, reducing the number of parts while maintaining electrical connectivity between battery stacks.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pressure vessel is designed to serve multiple functions simultaneously: it provides mechanical containment for the battery components and serves as the electrical conductor for current flow. This multi-functionality eliminates the need for dedicated connector components, simplifying the overall device structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional metal-hydrogen battery configurations with multiple connectors and bridge components are used, then electrical connectivity between stacks is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the electrical connection function directly into the pressure vessel structure by making the pressure vessel itself conductive. This eliminates the need for separate bridge connectors and intermediate stacks, reducing the number of parts while maintaining electrical connectivity between battery stacks.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and removes the unnecessary bridge connector components from the traditional battery configuration. By eliminating these redundant parts, the manufacturing process is simplified and material costs are reduced while the essential electrical connectivity function is preserved through the conductive pressure vessel.

Inventive Principle:

Principle #2Taking out (Extraction)

3Power

If bridge connections are used to connect battery stacks, then electrical current flows between stacks, but the number of welds and assembly steps increases

Engineering Contradiction:

Improvecurrent flowVSAvoidassembly efficiency

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The patent merges the electrical connection function directly into the pressure vessel structure by making the pressure vessel itself conductive. This eliminates the need for separate bridge connectors and intermediate stacks, reducing the number of parts while maintaining electrical connectivity between battery stacks.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250210723A1Nickel-Hydrogen Battery Configurations for Grid-Scale Energy Storage

Publication Date: 2025.06.26 ENERVENUE HLDG LTD

AI summary

A metal-hydrogen battery is presented. The battery includes a bridgeless CPV superstack having a number K of units, each unit including a first layer and a second layer, wherein the first layer includes a number L/2 of intermediate anode-cathodes, and wherein the second layer includes an end anode and an end cathode separated by L/2−1 intermediate anode-cathodes; a pressure vessel that encloses the bridgeless CPV superstack; and electrolyte within the pressure vessel. A bridgeless CPV superstack includes K units, each unit including a first layer and a second layer, wherein the first layer includes a number L/2 of intermediate anode-cathodes, and wherein the second layer includes an end anode and an end cathode separated by L/2−1 intermediate anode-cathode.