Multi-cell Flow Battery End Plate Sealing and Weight Reduction
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Solution Overview
Problem
Conventional flow batteries and fuel cells face challenges with electrolyte leakage and performance loss due to exposed components and graphite-based end plates, which exacerbate issues with weight, space utilization, and safety when cells are stacked to increase voltage.
Innovation Solution
A multi-cell structure is developed where all components, including electrolyte flow channels, are embedded within end plates, eliminating the need for gaskets and using PVC for the end plates, which are mated with a male tongue and female groove for sealing, allowing for higher voltage and reduced weight by integrating multiple cells into a single assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stacked structures with exposed components are used, then cell assembly is simpler, but electrolyte leakage and performance loss increase
Solution Approach 1:
The patent merges the end plate and gasket into a single integrated component. The end plate incorporates sealing surfaces and sealing structures directly formed as part of the plate body, eliminating the need for separate gasket components. This integration reduces the number of parts, simplifies assembly, and improves sealing reliability by eliminating interfaces between separate components where leakage could occur.
Solution Approach 2:
The patent implements a nested structure where multiple cells are housed within a common end plate assembly. The end plate contains recesses or cavities that accommodate individual cell components, creating a nested arrangement where cells are embedded within the end plate structure. This nesting approach protects exposed components and provides integrated sealing.
2Weight of moving object
If graphite-based end plates are used, then electrical conductivity is improved, but weight increases
Solution Approach 1:
The patent changes the material parameter of the end plate from graphite to a metal material such as stainless steel or aluminum alloy. This parameter change reduces the weight of the end plate while maintaining sufficient mechanical strength. The metal material provides adequate electrical conductivity for the application, resolving the contradiction between weight reduction and conductivity requirements.
Solution Approach 2:
The patent may employ composite material structures where the end plate is constructed from metal基体 with embedded conductive elements or coatings. This composite approach allows the primary structure to be made of lightweight metal while incorporating conductive pathways to maintain electrical conductivity performance.
3Power
If multiple cells are stacked to increase voltage, then energy output increases, but leakage issues are exacerbated
Solution Approach 1:
The patent merges multiple cell assemblies into a single integrated stack housed within a common end plate structure. The end plate incorporates sealing surfaces and sealing structures that seal around multiple cells simultaneously, creating a unified sealed environment. This approach allows multiple cells to be stacked for increased voltage while maintaining reliable sealing that prevents leakage, unlike individual sealed units stacked together where each interface is a potential leakage point.
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 effectively seals the structure, reduces weight, and enhances safety by encapsulating components, achieving higher voltage and energy output while minimizing leakage, and increasing power density through optimized surface area and component integration.
Implementation Method 1
One of the end plates has a projection along a perimeter of each of the recesses and the other one of the end plates has a groove along a perimeter of each of the recesses. The projection is configured to fit within the groove in a mating relationship to seal the housing when the end plates are engaged with each other.
Implementation Method 2
Fuel cells convert chemical energy generated from oxidation of hydrogen into electric energy. In operation, the cell processes a hydrocarbon fuel source to produce the hydrogen.
Implementation Method 3
A cathode fuel inlet supplies oxidant (typically air or oxygen) to the other electrode (the cathode) where electrons from the cathode combine with the oxygen and the hydrogen ions in the electrolyte to produce water.
Implementation Method 4
The bipolar plate, also called a flow-field plate, distributes an electrolyte solution inside flow battery cells, isolates different cells in multi-cell battery cores, conveys current into and out of cells, and dissipates the stack heat. The main role of the bipolar plate is to deliver reactants to and from porous anode and cathode materials via flow field channels.
Implementation Method 5
Conventional flow batteries include a cathode, an anode, a membrane separator, current collectors, gaskets, insulators, and reaction cells within a confined volume
Data Source
AI summary
A multi-cell electrochemical reaction cell structure for a flow battery or fuel cell having a plurality of cells electrically connected in series or parallel. A first housing has a pair of mating end plates assembled together, each forming a plurality of recesses in which one of the cells is received. One of the end plates has a projection along its perimeter and the other one of the end plates has a groove along its perimeter. The projection is configured to fit within the groove in a mating relationship to seal the housing when the end plates are engaged with each other. A second housing is a tubular shell in which a plurality of tubular flow cell units electrically connected in parallel are housed. Catholyte flows in the tubular flow cell units and anolyte flows in the tubular shell.