Electrode Module with Conductive Grille and Valve System
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Solution Overview
Problem
The existing metal-air electrochemical cells face challenges in achieving uniform filling and monitoring of cell capacity in stacks, leading to inefficiencies and complexities in manufacturing, with potential for electrolyte leakage and fault diagnosis issues due to disparate materials and intricate assembly processes.
Innovation Solution
The integration of electrode modules with a conductive grille for serial connection and a valve system for simultaneous flooding and electrolyte leveling, simplifying the assembly and reducing the need for extensive wiring, while using mating surfaces for improved sealing and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple cells are interconnected to form a stack to achieve higher voltages, then the voltage increases, but the filling time increases and filling uniformity deteriorates
Solution Approach 1:
The patent divides the battery system into modular electrode modules, each containing a limited number of cells (e.g., 10-100 cells per module). This segmentation allows each module to be filled independently and more quickly, then multiple modules are connected in series to achieve the desired total voltage. The modular approach resolves the contradiction by enabling parallel filling operations across multiple modules rather than sequential filling of all cells in a single large stack.
Solution Approach 2:
The patent introduces a valve system as an intermediary mechanism that controls electrolyte distribution across multiple cells. The valve enables simultaneous or coordinated filling of multiple cells through fluidic interconnection, dramatically reducing the total filling time while maintaining proper electrolyte levels in each cell. This intermediary device resolves the time penalty associated with connecting multiple cells in series.
2Power
If multiple cells are interconnected to form a stack to achieve higher voltages, then the voltage increases, but the monitoring complexity increases
Solution Approach 1:
The patent segments the monitoring task by assigning monitoring responsibilities to the modular electrode module level rather than individual cell level. Each module can be monitored as a unit, and the valve system provides centralized control for electrolyte distribution. This segmentation reduces monitoring complexity from thousands of individual cells to a manageable number of modules and valve control points.
Solution Approach 2:
The patent implements a feedback mechanism where the valve system monitors electrolyte levels and automatically adjusts distribution to maintain uniform filling across all cells. This closed-loop feedback reduces the need for manual monitoring of each cell while ensuring proper electrolyte levels are maintained throughout the stack.
3Reliability
If numerous components are assembled to manufacture each cell, then the cell functionality is achieved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple cell components into integrated electrode modules where cells are connected through shared structures and fluidic pathways. The valve system consolidates electrolyte distribution control for multiple cells into a single mechanism. This merging reduces the number of discrete assembly operations and simplifies the manufacturing process while maintaining all necessary cell functionalities.
Solution Approach 2:
The patent designs universal electrode modules that can be replicated and assembled in series to create batteries of various voltages and capacities. The modular design with standardized interfaces and the multi-functional valve system enable the same basic building blocks to serve multiple purposes, reducing manufacturing complexity through standardization and economies of scale.
4Adaptability or versatility
If disparate materials with varying porosity and surface finish are used for sealing, then the cell design flexibility is improved, but the sealing reliability deteriorates
Solution Approach 1:
The patent employs homogeneous sealing materials and standardized sealing surfaces across all electrode modules. This homogeneity ensures consistent sealing performance and reliability while the modular design maintains design flexibility through standardized interfaces that can be adapted to different battery configurations. The uniform sealing approach eliminates the reliability issues associated with disparate materials.
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 approach reduces manufacturing complexity, enhances reliability, and achieves higher open-circuit voltage with improved fault diagnosis and reduced filling time, making the system more efficient and cost-effective.
Implementation Method 1
the anode and cathode of each electrode module in a battery can be electrically interconnected using a conductive grille
Implementation Method 2
the compartments of said cells may be fluidically interconnected through a valve. This way, all cells can be flooded simultaneously
Implementation Method 3
a so-called air cathode or air electrode... During discharge of such cell, a reduction reaction occurs in the cathode
Implementation Method 4
the metal anode is oxidized
Data Source
Figure 1
Figure 2
AI summary
To achieve higher voltages in a metal-air electrochemical battery, several cells must be interconnected to form a modular unit known in the art as a "stack". These cells need to be filled one by one, which poses a major challenge as it results in uneven filling and thus differences in cell capacity. In a larger stack of several thousand cells, this may increase the time required for filling. Moreover, monitoring the fill level of all cells represents a significant issue. Further, the manufacturing of each cell involves numerous components to be assembled, requiring complex fabrication processes that are inherently inaccurate, error-prone, and expensive. Specifically, the cells need to be sealed against electrolyte leakage, encompassing a laborious joining procedure. Disparate materials of varying porosity and surface finish complicate this sealing process. The batteries resulting from such manufacture tend to be susceptible to faults whose diagnosis is often problematic: Failure of any one cell in the stack will cause the entire system to fail, entailing a cumbersome identification of the defective component. Solution Electrode module (EM) for an electrochemical cell, the module (EM) having a frame (11), characterized in a cathode (12), preferably integral with the frame (11), for maintaining an ion flow through an electrolyte in a compartment of the cell.