Folded Bipolar Plate Structure for Battery Gas Diffusion and Cooling
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Solution Overview
Problem
Existing metal-air and metal-liquid batteries face challenges in optimizing the design of bipolar plates for efficient gas diffusion and thermal management, which affects their performance and safety.
Innovation Solution
A bipolar plate design featuring a folded metal sheet with spaced loops forming flow field passages and internal passages, optionally incorporating thermal working materials and porous wicks, enhances gas diffusion and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional flat bipolar plate design is used, then the manufacturing process is simple, but gas diffusion efficiency and thermal management are insufficient
Solution Approach 1:
The bipolar plate is segmented into multiple loops arranged in series, creating distinct flow field passages between adjacent loops. This segmentation allows independent optimization of gas flow paths and current distribution, significantly improving gas diffusion efficiency while maintaining manufacturing simplicity through repetitive modular structures
Solution Approach 2:
The invention transitions from a traditional flat two-dimensional plate design to a three-dimensional folded structure with loops extending in multiple directions. This dimensional change creates vertical and horizontal flow paths that enhance gas distribution uniformity and improve thermal management capabilities without complicating the manufacturing process
2Productivity
If a folded loop structure is implemented, then gas diffusion and thermal management are improved, but the device complexity increases
Solution Approach 1:
The folded loop structure serves multiple functions simultaneously: it acts as current collector, defines flow field passages for gas distribution, provides thermal management channels, and creates reaction zones. This multi-functionality reduces the need for separate components, thereby improving thermal management efficiency without proportionally increasing device complexity
Solution Approach 2:
The loops are arranged in a nested or series configuration where each loop contains flow field passages within its folded structure. This nesting allows compact integration of multiple functional zones within a single plate component, enhancing thermal management efficiency while controlling overall structural complexity through space-efficient design
3Speed
If loops are spaced apart to form flow field passages, then mass transport is enhanced, but the area for current collection is reduced
Solution Approach 1:
The bipolar plate features non-uniform loop spacing with varying distances between adjacent loops across different regions. Areas with higher current density requirements have tighter loop spacing for maximum current collection, while regions requiring enhanced gas distribution have wider spacing for improved mass transport. This local quality variation optimizes both parameters simultaneously
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
Improves the efficiency and safety of metal-air and metal-liquid batteries by optimizing gas diffusion and thermal management, thereby enhancing their performance.
Implementation Method 1
A porous wick in the internal passages
Implementation Method 2
A further embodiment of any of the foregoing embodiments includes a thermal working material in the internal passages. In a further embodiment of any of the foregoing embodiments, the thermal working material is selected from the group consisting of a wax, a fire retardant, and a refrigerant
Implementation Method 3
The loops are spaced apart to define flow field passages therebetween on the second side
Data Source
AI summary
A bipolar plate for a battery includes a metal sheet that has a first side and a second, opposite side. The metal sheet is folded so as to form a series of loops on the second side. The loops are spaced apart to define flow field passages therebetween on the second side. Each of the loops is bonded along an edge at the first side so as to enclose an internal passage.