Chamber-Array Rechargeable Cell Layout for Low-Cost High Energy Density
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Solution Overview
Problem
There is a demand for low-cost, easily manufacturable rechargeable battery systems with high energy density for various applications, but lithium-ion batteries are limited by the availability of key metals and safety risks, necessitating the development of batteries using low-cost materials.
Innovation Solution
A rechargeable battery cell design featuring a first electrode material surrounded by a second electrode material, with a common collector array and separator allowing electrolyte-mediated ion flow, utilizing materials like zinc oxide and nickel hydroxide, and incorporating ion exchange materials and conductive current collectors for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If lithium-ion batteries are used to achieve high energy density, then energy storage performance is improved, but cost and safety issues worsen due to limited metal availability and safety risks
Solution Approach 1:
The battery is divided into multiple individual cells, each containing its own electrodes and electrolyte. This segmentation allows for modular assembly, improved safety containment, and easier manufacturing processes while maintaining high energy density through optimized cell design and arrangement.
Solution Approach 2:
The invention changes the chemical parameters by using alternative electrode materials (such as zinc oxide and nickel hydroxide) and electrolyte compositions to replace traditional lithium-ion materials. This substitution maintains electrochemical performance and energy density while eliminating dependence on scarce and expensive lithium metals, thereby reducing cost and safety concerns.
2Ease of manufacture
If traditional battery designs are used, then manufacturing processes are simple, but energy density and performance are limited
Solution Approach 1:
The battery design employs a nested structure where individual cell components (electrodes, separators, electrolytes) are contained within cell housings, which are then assembled into modules and ultimately into the complete battery system. This nested architecture simplifies manufacturing by enabling standardized sub-assembly processes while achieving high energy density through optimized space utilization and reduced dead weight.
3Quantity of substance
If high energy density materials are used, then energy storage capacity is improved, but safety risks and material availability issues worsen
Solution Approach 1:
The invention employs abundant, low-cost materials such as zinc oxide, nickel hydroxide, and aqueous electrolytes that can be readily replaced if needed. These materials provide sufficient energy storage capacity for most applications and eliminate the safety and availability concerns associated with lithium, cobalt, and other scarce metals used in high-energy-density lithium-ion batteries.
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
This design enables the creation of cost-effective, high-energy-density battery systems with enhanced safety and manufacturability, suitable for portable devices and electric vehicles, by leveraging materials like zinc oxide and nickel hydroxide, and optimizing the structure for efficient ion flow and electrical conductivity.
Implementation Method 1
a common collector array with a first electrode material, with each member of the collector array further including a second electrode material and a second electrode current collector
Implementation Method 2
incorporating ion exchange materials and conductive current collectors for improved performance
Data Source
AI summary
A rechargeable battery cell includes first and second electrode materials. A first collector defining a chamber array with a plurality of chambers is electrically connected to each other. A plurality of second electrode material and second collectors are positioned within each of the plurality of chambers. A first electrode material is positioned within the first collector to surround the second electrode material, with the second electrode material separated from the first electrode material by a separator.