Integral Manifold for Flowing Electrolyte Battery
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Solution Overview
Problem
Flowing electrolyte batteries face challenges in manufacturing due to complex and delicate connection apparatuses between cells, leading to energy losses and cell imbalances, and existing methods are difficult to manufacture and prone to damage.
Innovation Solution
A method of forming an integral manifold for a cell stack by creating a mould cavity adjacent the cell stack, inserting pins with specific dimensions, filling with material, and allowing it to solidify, then removing the pins and plug to form passages in fluid communication with capillary openings and a manifold cavity, enhancing the seal and reducing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If external manifolds with elastomer connection tubes are used to connect cells, then the battery can be assembled with separate cells, but the connection apparatus is delicate and prone to damage during assembly and use
Solution Approach 1:
The patent merges the manifold and connection tubes into a single integral manifold component. The manifold is formed as one piece with integrated flow paths and connection points, eliminating the need for separate elastomer connection tubes. This integration resolves the technical contradiction by maintaining assembly flexibility while dramatically improving durability, as the integral structure has no delicate separate connections that can be damaged during assembly or use.
2Adaptability or versatility
If external manifolds with multiple elastomer connection tubes are used, then each cell can be individually connected, but the manufacturing process becomes complex and difficult
Solution Approach 1:
The manifold is formed as a single integral piece using injection molding, combining multiple connection points and flow paths into one manufacturing step. This eliminates the complex assembly process of connecting multiple elastomer tubes to each cell, while still providing individual connection capability to all cells. The integral structure is manufactured as one component, dramatically simplifying the manufacturing process.
Solution Approach 2:
The manifold is pre-formed with all connection points and flow paths integrated during the injection molding process. The capillary openings are pre-positioned and the flow paths are pre-formed, eliminating the need for subsequent assembly steps to connect individual tubes to each cell. This preliminary formation of the complete connection system resolves the manufacturing complexity issue.
3Reliability
If electrolyte circulation paths are made sufficiently long to prevent shunt currents, then electrical resistance between cells increases, but the circulation path becomes more complex
Solution Approach 1:
The manifold uses a three-dimensional internal flow path structure that provides sufficiently long circulation paths for electrical isolation while maintaining a compact external footprint. The injection-molded manifold incorporates complex internal channels that extend electrolyte flow paths through the manifold body, achieving the required electrical resistance without increasing the overall device dimensions or external complexity.
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 method results in a more robust and sealed integral manifold that reduces energy losses and cell imbalances, improving the manufacturing process and reducing the risk of damage during assembly and use.
Implementation Method 1
allowing the material to solidify into a moulded section
Data Source
Figure 1
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AI summary
A method of forming passages of an integral manifold adjacent a cell stack (20) of a flowing electrolyte battery provides enhanced sealing between the manifold and capillary tubes of the cell stack (20). The method includes forming a mould cavity (44) adjacent the cell stack (20), with the mould cavity (44) open to capillary openings of cells of the cell stack (20). A plurality of pins (38) are then located in the mould cavity (44), with end regions of the pins (38) being contiguous with the capillary openings. The mould cavity (44) is then filled with material and the material is allowed to solidify into a moulded section. The pins (38) are then removed from the moulded section, thereby forming passages in the moulded section which are in fluid communication with the capillary openings.