Flowing-Electrolyte Lead-Acid Cell Formation Against Stratification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Lead acid batteries face challenges in achieving long cycle life and high depth of discharge due to issues like acid stratification, electrode sulfation, and non-uniform current distribution, which limit their suitability for large-scale stationary storage applications such as grid storage systems.
Innovation Solution
The method involves using multiple electrolytes with specific concentrations and flow rates to electrochemically fabricate and regenerate active materials within the battery casing, optimizing electrolyte flow to extend battery life, reduce manufacturing time and cost, and prevent electrode degradation, allowing for in-situ regeneration without physical disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lead acid batteries are used for stationary storage with deep charge/discharge cycling, then capacity utilization is improved, but cycle life deteriorates due to electrode sulfation and active material softening
Solution Approach 1:
The patent applies parameter changes by modifying the electrolyte concentration and composition during different operational phases. During formation, a high concentration electrolyte is used to promote active material deposition, while during operation, the electrolyte concentration is optimized to prevent sulfation and maintain cycle life, thus resolving the contradiction between capacity utilization and cycle life
Solution Approach 2:
The patent implements preliminary action through a formation process that pre-treats the electrodes before operational use. This formation process creates a stable electrode structure and prevents premature sulfation, thereby extending cycle life while maintaining high capacity utilization during subsequent deep charge/discharge cycles
2Quantity of substance
If acid stratification occurs during charge and discharge, then local material utilization varies, but overall cell efficiency deteriorates
Solution Approach 1:
The patent applies dynamics by implementing a flowing electrolyte system that dynamically redistributes the electrolyte during charge and discharge cycles. This prevents acid stratification by continuously moving the electrolyte to ensure uniform concentration distribution, thereby maintaining high cell efficiency while achieving uniform local material utilization across all electrodes
3Ease of manufacture
If traditional manufacturing processes are used, then manufacturing simplicity is maintained, but manufacturing time and cost increase for high-performance cells
Solution Approach 1:
The patent merges the formation process with the manufacturing process by conducting electrochemical formation in-situ within the battery cell during production. This eliminates the need for separate formation equipment and processes, reducing manufacturing time and complexity while producing high-performance cells with optimized electrode structures
Solution Approach 2:
The patent implements self-service by enabling the battery cell to perform its own formation process during manufacturing. The cell uses its own electrolyte and electrode structure to undergo electrochemical formation, eliminating the need for external formation equipment and simplifying the manufacturing process while improving cell performance
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 approach extends battery lifetime, reduces manufacturing and operational costs, and enhances cell efficiency, making lead acid batteries more suitable for long-duration energy storage applications by addressing the limitations of current manufacturing processes and degradation issues.
Implementation Method 1
an electrochemical cell. The electrochemical cell includes a housing, a negative electrode substrate disposed within a first electrode chamber of the housing, a positive electrode substrate disposed within a second electrode chamber of the housing
Implementation Method 2
pumping a first charge operation electrolyte having a first charge operation concentration at a first charge operation flow rate through the first electrode chamber
Data Source
AI summary
An electrochemical cell includes a housing, a positive electrode substrate disposed within a first electrode chamber of the housing, a negative electrode substrate disposed within a second electrode chamber of the housing, and a separator may be disposed within the housing between the first electrode chamber and the second electrode chamber. A method further includes pumping a manufacturing electrolyte through the positive electrode portion around the positive electrode substrate. The method further includes applying a first electrical signal to the positive electrode substrate so as to electrochemically fabricate one or both of an active material the negative electrode substrate to form a negative electrode and/or an active material on the positive electrode substrate, thereby forming a positive electrode.