Multi-Part Anode Extrusion Nozzle for High-Rate Cell Discharge
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Solution Overview
Problem
Current manufacturing techniques lack scalability for producing alkaline electrochemical cells with dual-anode configurations, which have shown improved high-rate discharge performance in small-scale tests, necessitating novel methods for large-scale production.
Innovation Solution
A method involving an extrusion nozzle with a hollow tubular body, lower deflector, and support rod to form anode portions with distinct characteristics within the electrochemical cell, allowing for the creation of a gradient anode structure by extruding anode material through an annular opening and a central conduit, enabling the formation of multiple anode portions with varying surfactant types and active material compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple anode portions are positioned concentrically within the cell to improve high-rate discharge performance, then discharge performance is improved, but device complexity increases
Solution Approach 1:
The anode is divided into multiple discrete anode portions (first anode portion, second anode portion, third anode portion) positioned concentrically within the cell. Each portion has distinct characteristics such as different surfactant types or active material compositions, allowing optimized discharge performance at different radial locations while maintaining manageable structural complexity through systematic arrangement
Solution Approach 2:
Different anode portions are assigned different local properties including varying surfactant concentrations, different active material compositions, or different porosity characteristics. This local differentiation enables each portion to optimize for specific discharge conditions, with inner portions handling high-rate discharge and outer portions providing additional capacity
2Manufacturing precision
If a nozzle with support rod and deflector is used to extrude anode material, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The nozzle is divided into functional segments including a hollow tubular body for material delivery, a support rod for structural stability, and a deflector for shaping control. This segmentation allows each component to be optimized independently for its specific function while assembling into a cohesive precision tool
Solution Approach 2:
The support rod acts as an intermediary structural element that maintains the integrity of the hollow tubular body during extrusion. The deflector serves as an intermediary shaping element that guides the anode material into the desired configuration, enabling precise formation without requiring overly complex nozzle designs
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 enhances high-rate discharge performance by ensuring uniform discharge and reducing gassing, as the anode portions with lower charge transfer resistance near the current collector discharge first, preventing zinc oxide formation near the separator, thus maintaining active material availability and improving overall cell performance.
Implementation Method 1
A method involving an extrusion nozzle with a hollow tubular body, lower deflector, and support rod to form anode portions with distinct characteristics within the electrochemical cell, allowing for the creation of a gradient anode structure by extruding anode material through an annular opening and a central conduit
Implementation Method 2
This approach enhances high-rate discharge performance by ensuring uniform discharge and reducing gassing, as the anode portions with lower charge transfer resistance near the current collector discharge first, preventing zinc oxide formation near the separator
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A nozzle is provided for providing anode material into an electrochemical cell and method of using the same. The nozzle comprises a hollow tubular body extending between an open upper end and an open lower end; a lower deflector spaced apart from the open lower end of the hollow tubular body and forming an annular opening between a deflection surface of the lower deflector and the open lower end of the hollow tubular body; and a support rod connecting the lower deflector with the hollow tubular body, wherein the support rod is suspended within an interior of the hollow tubular body by one or more support trusses.