Drone Electrolyte Docking for Rapid Metal-Air Battery Refill
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Solution Overview
Problem
Current metal air batteries, particularly aluminum air batteries, face limitations in power output over time due to electrolyte saturation, and drones powered by rechargeable lithium-ion batteries have restricted flight times and ranges, especially with heavy payloads, necessitating the development of more efficient power solutions for aerial applications.
Innovation Solution
A metal air battery electrolyte replenishment system featuring a base station with a docking receptor and a probe on the drone for rapid electrolyte exchange, allowing fresh electrolyte to be introduced and spent electrolyte to be expelled while in flight or during brief landings, enabling extended range and flight time without the weight and complexity of onboard reconditioning systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If lithium-ion batteries are used to power drones, then flight time and range are limited, but using internal combustion engines or fuel cells increases range and payload capacity
Solution Approach 1:
The patent changes the chemical composition and properties of the electrolyte (using potassium hydroxide or sodium hydroxide with specific concentrations) to enable metal air battery operation with high energy density comparable to hydrocarbon fuels, while maintaining safe operating parameters for aerial applications
Solution Approach 2:
The patent employs a composite power system combining metal air battery (for energy density), electrolyte management system (for operational control), and heat exchanger (for thermal management) to achieve both extended flight time and high payload capacity that neither component could provide alone
2Duration of action of moving object
If internal combustion engines with generators are installed on drones, then range and payload increase, but weight of support systems and storage of flammable materials increases
Solution Approach 1:
The patent extracts and eliminates the heavy support systems (fuel tanks, combustion chambers, exhaust systems) by replacing internal combustion engines with metal air batteries that use aluminum metal and electrolyte solutions, retaining only the essential electrolyte management components
Solution Approach 2:
The patent changes the energy storage medium from flammable hydrocarbon fuels to non-flammable metal air battery systems with high energy density, eliminating safety system weights while extending range
3Weight of moving object
If metal air batteries operate in batch mode, then power output decreases over time, but system weight is reduced
Solution Approach 1:
The patent implements continuous electrolyte circulation through the battery stack, allowing sustained aluminum dissolution and electricity generation without power degradation, while using a heat exchanger to maintain optimal operating temperatures for continuous operation
4Power
If metal air batteries operate in steady state mode, then power curve remains constant, but onboard electrolyte reconditioning system weight is added
Solution Approach 1:
The patent extracts the complex onboard electrolyte reconditioning system (crystallization chambers, filtration equipment) and replaces it with a simple electrolyte replenishment system that adds fresh electrolyte and removes spent electrolyte, maintaining constant power output with minimal equipment
Solution Approach 2:
Instead of attempting to recondition and recycle electrolyte onboard (complex process), the system inverts the approach by continuously replenishing fresh electrolyte and discarding spent electrolyte, achieving simpler system architecture with comparable performance
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 solution allows for extended flight times and increased payload capacity by facilitating rapid and efficient electrolyte replenishment, maintaining consistent power output and reducing the weight and complexity of the drone's power system.
Implementation Method 1
an electrolyte pump fluidly connected to the metal air battery
Implementation Method 2
a heat exchanger; an electrolyte pump fluidly connected to the metal air battery, the heat exchanger
Implementation Method 3
a vacuum pump for pumping electrolyte from the at least one drain hole to an electrolyte storage tank
Implementation Method 4
a feed pump for pumping electrolyte from an electrolyte tank to the aperture
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A metal air battery electrolyte replenishment system comprised of a base station with docking receptor apparatus and matching docking probe on a flying drone. The probe onboard the drone has a sensor that guides the drone to connect with the electrolyte docking receptor on the base station. The drone uses the probe to obtain fresh electrolyte and simultaneously expel spent electrolyte into the base station while still in flight or during a brief landing. Rapid exchange of the electrolyte allows for extended range and flight time without penalty of onboard electrolyte reconditioning system and its associated weight.