Redox Flow Battery Elastic Flange for Thermal Expansion Control
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Solution Overview
Problem
Redox flow batteries face challenges with thermal management, particularly due to disproportionate thermal expansion and contraction of components in the cell stack, leading to warping and reduced efficiency, especially when scaling up or stacking multiple batteries.
Innovation Solution
Incorporating an elastic flange with a recess mated to a conductive plate and a plate frame that accommodates thermal expansion, allowing for longitudinal compliance and reducing the risk of warping, along with a compression assembly using leaf springs to maintain stack integrity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the cell stack size is increased or multiple stacks are included in a single battery module, then the power and capacity of the battery are improved, but the thermal management challenges are exacerbated and warping is more likely to occur
Solution Approach 1:
The battery system is divided into multiple modular battery modules, each containing its own cell stack assembly with integrated compression assembly. This segmentation allows each module to be independently managed thermally and structurally, enabling scaling of power and capacity while maintaining reliability through modular replication rather than creating one large unmanageable stack.
Solution Approach 2:
The compression assembly dynamically adjusts the compression force parameter applied to the cell stack based on thermal conditions and operational state. By changing the compression parameter in response to thermal expansion/contraction, the system maintains optimal structural integrity and thermal contact across varying operating conditions, preventing warping even in large-scale configurations.
2Ease of manufacture
If rigid bonding methods (adhesive bonding) are used to attach the flange to the plate frame, then the manufacturing process is simplified, but the interface strength is reduced and decoupling may occur under thermal stress
Solution Approach 1:
The patent replaces chemical adhesive bonding with a mechanical compression system. The compression assembly applies continuous mechanical force to press the flange against the plate frame, creating a strong friction-based mechanical interface that is superior to adhesive bonding in withstanding thermal cycling stresses, while remaining equally simple to manufacture.
Solution Approach 2:
The connection interface combines multiple materials and mechanisms: the flange material, the plate frame material, and the compression force create a composite mechanical-thermal interface. This composite approach leverages the strengths of each component to achieve both ease of manufacture and high interface strength under thermal stress.
3Ease of manufacture
If conventional rigid cell stack designs are used, then the manufacturing is simpler, but the components cannot accommodate disproportionate thermal expansion/contraction leading to warping
Solution Approach 1:
The compression assembly introduces dynamic adaptability to the cell stack design. Rather than a static rigid structure, the compression force can dynamically adjust to accommodate thermal expansion and contraction of different components at different rates. This dynamic characteristic allows the system to adapt to thermal stresses without warping, while the modular nature keeps manufacturing simple.
Solution Approach 2:
The compression assembly acts as an intermediary element between the cell stack components and the external environment. It mediates the thermal stresses by providing a compliant mechanical interface that absorbs differential expansion/contraction, protecting the rigid components from warping while maintaining overall structural integrity.
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 solution effectively reduces the likelihood of unwanted warping and enhances the structural integrity and efficiency of the battery, enabling cost-effective scaling and modular design while maintaining performance.
Implementation Method 1
The elastic flange accommodates for cell stack expansion/contraction caused by thermal gradients in the stack
Implementation Method 2
Heat welding the elastic flange to the plate frame allows adhesive bonding between the flange and the frame to be omitted
Data Source
AI summary
A redox flow battery and battery system are provided. In one example, the redox flow battery includes a cell stack assembly having a plate assembly positioned on a lateral side of the cell stack assembly and comprising an elastic flange including a recess mated with a section of a conductive plate and compliant in at least one of a lateral direction and a vertical direction, and a plate frame coupled to the elastic flange.