Sealed Electrochemical Cell Stacks for Corrosion-Free High Density

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Electrochemical cell stacks face issues with galvanic corrosion due to exposure of dissimilar metals, leading to performance degradation and increased risk of corrosion, while also suffering from inefficient space utilization and dead volume, which affects performance and efficiency.

Innovation Solution

The implementation of seal members around the perimeter of electrochemical cells, using materials that prevent vapor ingress and isolate anode and cathode current collectors, combined with the use of semi-solid electrodes that reduce tortuosity and increase active material content, thereby minimizing galvanic corrosion and optimizing space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If electrochemical cells are stacked to increase voltage and capacity, then power density and energy density are improved, but metal current collectors are exposed to vapor ingress causing galvanic corrosion

Engineering Contradiction:

Improvepower densityVSAvoidcorrosion resistance

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

A seal member is introduced as an intermediary component between adjacent electrochemical cells in the stack. This seal member prevents vapor ingress to the metal current collectors, thereby eliminating galvanic corrosion while maintaining the stacked configuration for high power density

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The seal member creates a protected environment around the metal current collectors by preventing exposure to corrosive vapors. This effectively isolates the metal components from the harmful atmospheric conditions that would otherwise cause galvanic corrosion

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Quantity of substance

If electrochemical cells are stacked to increase capacity, then energy density is improved, but dead volume increases affecting electrolyte flow and current distribution

Engineering Contradiction:

ImprovecapacityVSAvoiddead volume

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The seal member is designed as a thin-film structure that provides necessary sealing functionality while minimizing volume occupation. This reduces dead volume in the stacked cell configuration, improving electrolyte flow and current distribution while maintaining high capacity

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The seal member is positioned at the peripheral edges of the cells rather than occupying central volume space. This strategic placement in a different spatial dimension (perimeter vs. core volume) effectively seals the cells while minimizing impact on the active volume available for electrolyte flow and current distribution

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250349950A1Sealed electrochemical cells and electrochemical cell stacks

Publication Date: 2025.11.13 24M TECHNOLOGIES INC

AI summary

Embodiments described herein relate to sealed electrochemical cells and multi-cells. An electrochemical cell includes a cathode disposed on a cathode current collector. The cathode current collector including a first layer disposed on the cathode and a second layer disposed on the first layer. The first layer includes a first material, and the second layer includes a second material different from the first material. The electrochemical cell further includes an anode disposed on an anode current collector. The anode current collector includes the second material. A separator is disposed between the cathode and the anode.