Integral Manifold Forming for Flowing Electrolyte Batteries

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Solution Overview

Problem

Flowing electrolyte batteries face challenges such as shunt currents, energy losses, and leaks due to the complexity and fragility of their electrolyte circulation paths and connection apparatus, particularly in high-pressure injection molding processes that can deform soft, porous plastic components.

Innovation Solution

A method of forming an integral manifold for a flowing electrolyte battery that involves pre-heating the mould cavity with molten material, using a manifold core with pins that cool simultaneously to prevent deformation, and filling the cavity with molten material at lower pressures, ensuring a strong bond and reducing the likelihood of leaks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high-pressure injection molding is used to form the integral manifold, then manufacturing efficiency and bonding strength are improved, but soft porous plastic components deform and leaks occur

Engineering Contradiction:

Improvebonding strengthVSAvoidcomponent integrity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The method applies preliminary heating to the mold cavity and inserted plastic parts before the main injection process. This pre-heating action prepares the materials by raising their temperature to facilitate bonding, allowing the subsequent injection to occur at lower pressures that won't deform the soft porous plastic components while still achieving strong bonds.

Inventive Principle:

Principle #10Preliminary action

2Strength

If high injection pressure is applied, then molten material bonds strongly to the cell stack, but soft porous plastic components deform

Engineering Contradiction:

Improvebond strengthVSAvoidcomponent shape

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The invention changes the temperature parameter of the mold cavity and inserted parts before injection. By heating these components to elevated temperatures, the material becomes more receptive to bonding at lower pressures. This parameter change allows achieving strong bond strength without applying high injection pressure that would deform the soft porous plastic components.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If external manifolds with elastomer connection tubes are used, then electrolyte circulation is achieved, but the connection apparatus is fragile and prone to damage

Engineering Contradiction:

Improveelectrolyte circulationVSAvoidconnection durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The invention merges the manifold structure with the battery casing by forming an integral manifold directly within the casing material. This combines previously separate components (external manifold and casing) into a single integrated structure, eliminating the fragile elastomer connection tubes and their delicate connections while maintaining electrolyte circulation functionality.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If integral manifolds are formed within the casing, then connection durability is improved, but bonding weaknesses and leaks can occur

Engineering Contradiction:

Improveconnection durabilityVSAvoidbond quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The method applies preliminary heating to the mold cavity and inserted plastic parts before the main injection process. This pre-heating ensures proper bonding by raising the temperature to facilitate material flow and adhesion, preventing bonding weaknesses and leaks while maintaining the durability benefits of the integral manifold design.

Inventive Principle:

Principle #10Preliminary action

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 method enhances bonding between the molten material and the cell stack, reduces the risk of leaks, and allows for lower injection pressures, maintaining the integrity of soft plastic components while improving the structural integrity and efficiency of the battery's electrolyte flow system.

Implementation Method 1

pre-heating the mould cavity by passing a molten material into a first end of the mould cavity and out of a second end of the mould cavity

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

with the pins being cooled simultaneously

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10549462B2Method of forming an integral manifold

Publication Date: 2020.02.04 REDFLOW PTY LTD

AI summary

A method of forming an integral manifold adjacent a cell stack of a flowing electrolyte battery enables improved bonding of a molten material to the battery cell stack. The method includes defining a mould cavity adjacent the cell stack, with the mould cavity open to capillary openings of half cells of the cell stack; locating a plurality of pins in the mould cavity, with end regions of the pins being contiguous with the capillary openings; preheating the mould cavity by passing a fluid into a first end of the mould cavity and out of a second end of the mould cavity; and filling the mould cavity with molten material.