Flexible Metal-Air Battery Case for Constant Electrode Spacing

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Solution Overview

Problem

Existing metal-air fuel batteries using large-sized metal plates face performance degradation due to increasing distance between the anode and cathode during chemical reactions, leading to unsustainable and unstable electrochemical reactions.

Innovation Solution

A metal-air fuel battery system with a flexible case and follow-up adjustment mechanism that adjusts the shape of the case in real-time to maintain a constant distance between the anode and cathode, using a drive mechanism and flexible rubber material to accommodate a large-sized metal ingot, along with an electrolyte solution circulation system for sedimentation and purification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If large-sized metal ingots are used as anodes to reduce replacement frequency, then productivity is improved, but the distance between anode and cathode increases during reaction, causing reliability to deteriorate

Engineering Contradiction:
Improveanode replacement frequencyVSAvoidelectrochemical reaction stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent applies the dynamics principle by making the battery case flexible and capable of changing shape. The case transitions from a rigid fixed structure to a dynamic flexible structure that can adapt its internal volume. The flexible case is driven by a driving mechanism that adjusts the case's shape based on the remaining amount of metal ingot, thereby dynamically maintaining the optimal distance between anode and cathode throughout the reaction process.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent applies the parameter changes principle by changing the physical state and geometric parameters of the battery case. The case changes from a fixed rigid state to a variable flexible state, with its internal volume and shape parameters being adjusted according to the reaction progress. The driving mechanism modifies the case's geometric parameters (length, width, height) to compensate for the decreasing anode volume, ensuring constant electrode spacing.

Inventive Principle:
Principle #35Parameter changes

2Device complexity

If rigid fixed battery cases are used, then device complexity is reduced, but the electrochemical reaction becomes unsustainable, causing reliability to deteriorate

Engineering Contradiction:
Improvebattery case structureVSAvoidreaction sustainability
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent transforms the static rigid case into a dynamic flexible case with adjustable geometry. The flexible case incorporates a driving mechanism that actively adjusts the case's internal volume based on feedback about the metal ingot's remaining amount, enabling the system to adapt to changing reaction conditions and maintain optimal electrochemical performance throughout the battery's operational life.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements a feedback control system where the driving mechanism monitors the remaining amount of metal ingot and adjusts the flexible case's shape accordingly. This feedback loop ensures that the distance between anode and cathode is continuously maintained at the optimal value, preventing reaction instability and extending the battery's sustainable operational period.

Inventive Principle:
Principle #23Feedback

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

Ensures continuous and stable electrochemical reactions by maintaining a consistent anode-cathode distance, enhancing the performance reliability and efficiency of the battery.

Implementation Method 1

push walls of the flexible case to deform elastically under action of an external force so as to compress inwards

Methodology Applied
Scientific EffectElastic deformation: Elasticity

Implementation Method 2

performing sedimentation and purification under certain conditions

Methodology Applied
Scientific EffectSedimentation: Sedimentation

Data Source

PatentUS20260031437A1Metal-air fuel battery system with follow-up adjustment of large-sized anode
Publication Date: 2026.01.29 TRANSLATIONAL RES CENT SCHOOL OF MECHANICAL & VEHICLE BEIJING INST OF TECH TANGSHAN PORT ECONOMIC DEV ZONE
  • US20260031437A1 patent drawing
  • US20260031437A1 patent drawing
  • US20260031437A1 patent drawing

AI summary

A metal-air fuel battery system with follow-up adjustment of a large-sized anode is provided, which relates to a technical field of a battery. The battery system includes a flexible case, a follow-up adjustment module and a drive mechanism, where the flexible case, as an electrochemical reaction space, is configured to accommodate an electrolyte solution and a metal ingot therein, and have a flexible air electrode embedded in an inner wall thereof; the follow-up adjustment module is configured to change a shape of the flexible case according to a size change of the metal ingot, to reduce the electrochemical reaction space; and the drive mechanism is configured to control action of the follow-up adjustment module.