Double-Stack Iron Flow Battery Layout for Lower Weight Scaling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The cost and weight of multi-iron redox flow battery (IFB) systems increase significantly when multiple units are required to meet energy demands, due to the need for multiple sets of components such as pressure plates and hardware, which escalates overall costs and weight burdens.
Innovation Solution
A double-stack redox flow battery system is configured with two IFBs stacked vertically, coupled via nesting detents, allowing for adjustable operation based on power demand, reducing the number of hardware components and maintaining a compact footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple individual IFBs are used to meet energy demand, then energy storage capacity increases, but system weight and cost increase significantly due to multiple sets of components
Solution Approach 1:
The patent combines multiple IFB units into a single integrated battery system with a shared pressure plate structure. The pressure plate serves multiple cell stacks simultaneously, eliminating the need for separate pressure plates in each individual IFB. This merging approach maintains the required energy storage capacity while significantly reducing the total number of hardware components, thereby decreasing system weight.
Solution Approach 2:
The pressure plate is designed as a universal component that performs multiple functions across different cell stacks. A single pressure plate can apply compression force to multiple IFB units, providing both structural support and electrical isolation simultaneously. This multi-functional design reduces the overall component count and system weight while maintaining the necessary energy storage capacity.
2Quantity of substance
If multiple individual IFBs are used to meet energy demand, then energy storage capacity increases, but manufacturing cost increases due to multiplicity of components
Solution Approach 1:
The patent merges multiple IFB units into an integrated system where common components like pressure plates are shared across multiple cell stacks. This reduces the total number of parts that need to be manufactured and assembled, thereby lowering manufacturing costs while maintaining the required energy storage capacity through the combined operation of multiple stacks.
Solution Approach 2:
The pressure plate is designed as a universal component that can serve multiple IFB units simultaneously. This multi-functionality reduces the overall component count, simplifying the manufacturing process and reducing costs. The universal pressure plate design allows for standardized production, further reducing manufacturing expenses while achieving the desired energy storage capacity.
3Quantity of substance
If multiple individual IFBs are used to meet energy demand, then energy storage capacity increases, but system complexity increases due to multiple hardware components
Solution Approach 1:
The patent combines multiple IFB units into a single integrated system with shared structural and electrical components. The pressure plate serves as a common element for multiple cell stacks, reducing the number of discrete hardware components. This merging approach maintains the required energy storage capacity while simplifying the overall system architecture and reducing complexity.
4Quantity of substance
If multiple individual IFBs are used to meet energy demand, then energy storage capacity increases, but footprint increases reducing compactness
Solution Approach 1:
The patent merges multiple IFB units into a vertically integrated stack configuration where multiple cell stacks share common structural components. This vertical stacking approach allows the system to achieve increased energy storage capacity without proportionally increasing the horizontal footprint, thereby maintaining system compactness while scaling energy storage capability.
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 configuration enhances energy storage capacity while reducing manufacturing costs and weight, allowing for efficient and scalable energy storage without proportional increases in hardware components.
Implementation Method 1
The iron redox flow battery (IFB) relies on iron, salt, and water for electrolyte
Implementation Method 2
Redox flow batteries may be suitable for grid scale storage applications due to their capability for scaling power and capacity independently
Data Source
AI summary
Methods and systems are provided for a redox flow battery system. In one example, the redox flow battery system has a first redox flow battery and a second redox flow battery, stacked above and in contact with the first redox flow battery along a vertical axis of the redox flow battery system. The second redox flow battery may be coupled to the first redox flow battery via nesting detents. Furthermore, operation of the first redox flow battery and the second redox flow battery may be adjustable according to a power demand.