Metal-Air Cell Negative Electrode Case With Porous Separator

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional metal-air cells face issues with dendrite growth and short circuits due to misalignment of electrodes and uneven deposit of active material, leading to deterioration in cycle characteristics.

Innovation Solution

A metal-air cell design with a negative electrode case having a porous structure unit and a lead extending out of the cell case without contacting the electrolyte, along with a method for manufacturing this configuration, which includes forming a closed-bottomed bag-like negative electrode case with a separator to prevent dendrite deposition and ion permeation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the separator is merely stacked without securing, then the device complexity is reduced, but the reliability deteriorates due to misalignment and dendrite growth

Engineering Contradiction:

Improvestructure complexityVSAvoidshort circuit risk

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent merges the separator with the negative electrode case by providing the separator at the opening of the negative electrode case, integrating two previously separate components into one unified structure. This eliminates the need for separate stacking and securing operations while ensuring reliable positioning and preventing dendrite growth.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separator is nested within the negative electrode case structure, specifically positioned at the opening of the case. This nested configuration allows the separator to be securely held by the case structure itself, preventing misalignment while maintaining a compact design without adding external securing components.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of manufacture

If the lead contacts the electrolytic solution, then the ease of manufacture is improved, but the reliability deteriorates due to dendrite generation and short circuit risk

Engineering Contradiction:

Improveassembly simplicityVSAvoiddendrite growth prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent extracts the lead from direct contact with the electrolytic solution by routing it through the negative electrode case structure. The lead is positioned to extend from the negative electrode through the case opening, where the separator provides insulation, preventing contact between the lead and electrolyte while maintaining manufacturing simplicity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The separator acts as an intermediary between the lead and the electrolytic solution. By positioning the separator at the opening of the negative electrode case, it creates a protective barrier that prevents direct contact between the lead and electrolyte, eliminating dendrite generation risk while requiring no additional manufacturing steps.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the separator is not provided at the opening, then the device complexity is reduced, but the manufacturing precision deteriorates due to misalignment

Engineering Contradiction:

Improvecomponent quantityVSAvoidelectrode alignment

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent combines the separator provision with the negative electrode case structure, where the case itself provides the positioning framework. The separator is integrated at the opening of the case, ensuring precise alignment with the negative electrode without requiring separate alignment operations or additional positioning components.

Inventive Principle:

Principle #5Merging (Combining)

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 design effectively reduces dendrite growth and the risk of short circuits, enhancing the cell's performance and stability by maintaining reliable insulation between electrodes.

Implementation Method 1

the negative electrode case includes a porous structure unit of insulation

Methodology Applied

Scientific EffectInsulation: Dielectric

Implementation Method 2

the opening is provided with a separator having a porous structure of insulation and acting as the porous structure unit

Methodology Applied

Scientific EffectPermeation barrier: Semipermeable Membrane

Data Source

PatentUS11705594B2Metal-air cell, and method for manufacturing metal-air cell

Publication Date: 2023.07.18 SHARP KK

AI summary

A metal-air cell comprises a negative electrode, a negative electrode case housing the negative electrode, sealed while a lead of the negative electrode extends from the negative electrode case, including a separator that forms at least part of the negative electrode case, an air electrode facing the negative electrode across the separator, and a cell case housing the negative electrode case and the air electrode and sealed while the lead of the negative electrode expands from the cell case and a lead of the air electrode expands from the cell case.