Protected Lithium Electrode Stack for Shock-Resistant Water Batteries

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Solution Overview

Problem

Existing lithium water-activated reserve batteries face challenges in ruggedization to withstand shock and vibration during shipping, transport, and deployment in marine environments, particularly in limited spaces with weight restrictions, while maintaining high energy density and manufacturability.

Innovation Solution

A compact, scalable electrode stack structure with a shock-absorbing member, composed of materials that absorb axial forces and dissipate energy, is integrated into the battery design, ensuring mechanical strength without compromising volume or energy density. This includes a transient shock-absorbing spacer between electrodes that is chemically compatible and dissolves after deployment, maintaining electrochemical performance and minimizing volume impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If shock-absorbing members are added to ruggedize the battery, then the battery can withstand shock and vibration during shipping and deployment, but the volume of the battery increases

Engineering Contradiction:

Improveshock and vibration resistanceVSAvoidbattery volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent employs thin flexible shock-absorbing members positioned between electrodes in the electrode stack. These thin film structures provide shock absorption capability while maintaining a compact overall battery volume, resolving the contradiction between ruggedization and volume constraints.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The shock-absorbing members are integrated within the existing electrode stack structure, nesting the protective function inside the battery's internal architecture rather than adding external protective layers. This allows shock protection without significantly increasing the battery's external dimensions.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If shock-absorbing members are added to ruggedize the battery, then the battery can withstand shock and vibration during shipping and deployment, but the weight of the battery increases

Engineering Contradiction:

Improveshock and vibration resistanceVSAvoidbattery weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The use of thin film shock-absorbing members minimizes the added weight while providing adequate shock protection. The thin film structure offers a high strength-to-weight ratio, allowing ruggedization without significantly burdening the battery's weight constraints for marine applications.

Inventive Principle:

Principle #30Flexible shells and thin films

3Quantity of substance

If the battery is designed for high energy density with compact electrode stack, then the energy density is maximized, but the battery becomes more susceptible to damage from shock and vibration

Engineering Contradiction:

Improveenergy densityVSAvoidshock and vibration resistance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The shock-absorbing members are pre-positioned between the electrodes during battery assembly, providing protective cushioning before the battery undergoes shock or vibration events. This beforehand protection allows the battery to maintain a compact, high energy density design while being pre-equipped to withstand mechanical stresses during shipping and deployment.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

The ruggedized lithium water-activated battery effectively withstands shock and vibration, maintaining high energy density and manufacturability, with minimal energy density reduction and cost penalty, suitable for marine applications like sonobuoys and ocean bottom sensors.

Implementation Method 1

a shock absorbing member 130, configured in the electrode stack to absorb axial forces and dissipate energy of a shock force associated with a waterbody impact

Methodology Applied

Scientific EffectShock absorption: Damping

Implementation Method 2

a transient shock-absorbing spacer between electrodes that is chemically compatible and dissolves after deployment

Methodology Applied

Scientific EffectDissolution: Solvation

Data Source

PatentUS20240429404A1Water activated batteries based on protected lithium electrodes

Publication Date: 2024.12.26 POLYPLUS BATTERY CO INC

AI summary

A high energy density lithium water-activated battery having a compact, readily manufacturable, and scalable electrode stack structure has enhanced tolerance to stress conditions such as shock and vibration, which may be experienced during shipping, transport and/or deployment into a waterbody (e.g., an ocean). A Li seawater battery pack can provide power to a marine device deployed in or on the surface of a waterbody via one or more seawater battery modules and a power circuit module having one or more input terminals for receiving battery voltages from the one or more battery modules. The power module conditions each of the battery voltages and consolidates these into a single operating output voltage, and the cathode electrodes from each of the battery modules share a common electrolyte comprising water from the waterbody.