Foil-Based Redox Flow Battery Weight Reduction
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Solution Overview
Problem
Conventional redox flow batteries face issues with the use of expensive and rare elements, leakage of ions through membranes, and the need for large, heavy electrodes, limiting their practical application and efficiency.
Innovation Solution
A foil-based redox flow battery where voltage is generated on thin metal foils acting as ion-exchange membranes, eliminating the need for traditional electrodes and reducing the overall size and weight by using aqueous solutions and ion-selective membranes to connect galvanic cells in series.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional electrodes are used in redox flow batteries, then voltage can be generated through redox reactions, but the battery becomes large, heavy, and expensive due to the need for large electrode surfaces and rare materials
Solution Approach 1:
The patent merges the functions of the electrode and the ion-exchange membrane into a single component. The metal foil serves both as the electron-conducting electrode and as the ion-selective separator, eliminating the need for separate large-area electrodes and heavy membrane assemblies. This integration directly reduces battery weight while maintaining voltage generation through redox reactions.
Solution Approach 2:
The metal foil electrode performs multiple functions simultaneously: it conducts electrons for voltage generation, separates the two electrolyte solutions, and provides ion-selective transport properties. This multi-functionality eliminates the need for dedicated heavy electrodes, reducing overall battery weight while preserving electrical performance.
2Power
If traditional electrodes and membranes are used, then redox reactions can occur, but the battery becomes expensive due to the use of rare and expensive materials
Solution Approach 1:
The patent replaces expensive traditional electrode materials (such as platinum, graphite, or other rare materials) with inexpensive metal foils. While the foil may be consumable and require replacement over time, the initial manufacturing cost is dramatically reduced, making the battery more economically viable despite the trade-off in long-term durability.
3Adaptability or versatility
If ion-exchange membranes are used to separate electrolytes, then different redox agents can be used in each compartment, but ion leakage occurs through the membrane reducing efficiency
Solution Approach 1:
The metal foil electrode combines the ion-exchange membrane function with the electrode function in a single component. This integration creates a tighter seal and more effective ion-selective barrier, reducing ion leakage while maintaining the ability to use different redox agents in each compartment. The foil's dual functionality eliminates gaps between separate electrode and membrane components.
4Power
If large electrodes are used to generate sufficient voltage, then power output increases, but the battery size and weight increase significantly
Solution Approach 1:
By integrating the electrode and membrane functions into a single thin metal foil, the patent achieves high power output without requiring large battery volume. The foil provides sufficient surface area for redox reactions while occupying minimal space, enabling compact battery design that maintains high power density.
Solution Approach 2:
The thin metal foil electrode provides sufficient active surface area for voltage generation while occupying minimal volume. The foil's thin-film structure enables high power output in a compact form factor, dramatically reducing battery volume compared to traditional thick electrode designs.
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
The battery is smaller, lighter, safer, and cheaper, with reduced ion leakage and the ability to use inexpensive materials, offering improved energy density and longer lifespan due to continuous regeneration of redox agents, making it suitable for electric grids and other applications.
Implementation Method 1
voltage is generated not on two different redox electrodes (cathode and anode) but on an electron-conducting foil, separating two solutions with different redox active substances
Implementation Method 2
an electron-conducting foil, separating two solutions with different redox active substances
Implementation Method 3
galvanic cells are connected one to another via walls made of ion-exchange membrane
Implementation Method 4
transport of ions through the membrane is described by Ohm's law
Data Source
AI summary
A flow-through redox galvanic cell and a battery is described, where each flow-through galvanic cell is separated into two parts by a metal foil serving as a bi-electrode in contact with two solutions having different redox potentials. Voltage due to redox processes is formed through the foil, and two traditional electrodes (cathode and anode) in each cell are not necessary anymore. The cells in a battery should be in electric contact with each other via ion-selective membranes. The battery is easy to recharge, and it is smaller, lighter, safer and cheaper than known redox-flow batteries. It may be used as a reserve source of energy in electric grids and households. It also may be used in electric cars, and it is especially attractive for use near the seashore and on sea ships.