Open Pool Battery Module With Permeable Electrodes and No Cell Seals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery designs with liquid electrolytes face challenges in manufacturing due to complex sealing requirements, high material costs, and assembly complexity, particularly with bipolar electrodes, which limit the use of materials and increase production costs.
Innovation Solution
A static, open pool battery design where conductive electrodes of the same polarity are electrically connected via a common bus and suspended in a common electrolyte pool, eliminating the need for individual cell seals and separators, and using a non-conductive elastomer or resin battery box for assembly, allowing for a simpler and more cost-effective construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bipolar battery electrodes are assembled by joining separate modular subassemblies using compression seals, infrared welding, laser welding, vibration welding, or adhesive seals, then sealing between adjacent cells and between cells and the environment is achieved, but manufacturing complexity increases, manufacturing cost increases, and assembly time increases
Solution Approach 1:
The patent merges multiple separate modular subassemblies into a single integrated electrode structure where bipolar electrodes are directly connected without requiring external seals or welding. The electrolyte reservoir serves as both the containment structure and the medium that electrically connects all electrodes, eliminating the need for separate sealing components between cells.
Solution Approach 2:
The electrolyte reservoir performs multiple functions simultaneously: it contains the electrolyte, provides electrical connection between all electrodes through the electrolyte medium, and serves as the structural housing. This multi-functionality eliminates the need for separate sealing components and simplifies the overall assembly.
2Strength
If multiple modular parts are assembled together with rigid metal electrodes, then electrical connection and structural integrity are achieved, but the number of complex modular parts increases manufacturing cost and requires high levels of process control and tolerancing
Solution Approach 1:
The patent changes the material parameter from rigid metal electrodes to flexible conductive polymer electrodes. This material substitution allows for direct integration of electrodes into the reservoir structure without requiring high-precision tolerancing or complex assembly processes, while maintaining electrical conductivity and structural integrity.
3Device complexity
If conductive plastic electrodes are co-injection molded with the frame or battery casing, then integration is achieved, but material selection is severely limited to only a small subset of materials capable of being injection molded
Solution Approach 1:
The patent segments the electrode material into a composite structure consisting of a flexible polymer matrix combined with conductive fillers (such as carbon black, graphite, or metal particles). This segmentation allows the base polymer to provide flexibility and processability while the conductive filler provides electrical conductivity, enabling a wide range of material selections beyond what is available through co-injection molding alone.
4Reliability
If high volume fraction of conductive diluents is used in conductive plastic electrodes, then electrical conductivity is improved, but welding and injection molding become difficult
Solution Approach 1:
The patent employs composite material construction where conductive polymer electrodes are formed by combining a flexible polymer matrix with dispersed conductive filler particles. This composite approach allows optimization of both electrical conductivity (through filler content and distribution) and weldability (through the polymer matrix), resolving the contradiction between high conductivity and ease of manufacturing.
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 simplifies battery manufacturing, reduces costs, and maintains energy density while eliminating key cost drivers and points of failure, enabling high-capacity batteries with improved reliability and reduced manufacturing complexity.
Implementation Method 1
The electrode material is porous to allow the electrolyte to flow through and wet the electrode material
Implementation Method 2
The cathodes and anodes are very permeable
Implementation Method 3
aqueous electrolyte solution that is ionically conductive
Implementation Method 4
The battery is a static, open pool battery which may have conductive electrodes of the same polarity electrically connected to one another
Data Source
AI summary
A battery module that is a static, open pool single cell battery which may have electrode elements of the same polarity spaced apart but electrically connected in parallel to one another and suspended from a common bus into a common electrolyte pool, in addition to a battery box that receives a plurality of electrode elements into the common electrolyte pool for the open pool battery. The electrode elements are alternating cathode elements and anode elements. A method for manufacture of the battery module is also described.