Ultrasonic Electrolyte Infiltration for Faster Battery Cell Wetting
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Solution Overview
Problem
Current methods for filling larger battery cells with liquid electrolyte are inefficient, requiring extended times due to slow infiltration into porous electrodes, leading to parasitic reactions and incomplete wetting.
Innovation Solution
A system utilizing a transducer to generate a wave, positioned in conjunction with a battery cell to create a standing wave, which accelerates electrolyte infiltration by increasing kinetic energy and reducing surface tension without the need for submersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed volume piston or pouring method is used to fill larger battery cells, then the cell filling process can be simplified, but the electrolyte infiltration time becomes unacceptably long (multiple hours)
Solution Approach 1:
The patent applies ultrasonic vibration to the battery cell during electrolyte filling. The ultrasonic transducer generates high-frequency mechanical vibrations that accelerate electrolyte infiltration into the porous electrodes by disrupting surface tension and enhancing capillary action, thereby reducing filling time from multiple hours to minutes while maintaining process simplicity.
Solution Approach 2:
The patent changes the physical state parameters of the electrolyte or cell environment during filling. By applying ultrasonic energy, the system temporarily alters the kinetic energy and surface tension characteristics of the electrolyte, enabling faster penetration into the electrode structure without requiring complex multi-step procedures.
2Device complexity
If multiple cells are placed together in a vacuum chamber for batch processing, then equipment complexity is reduced, but electrolyte spilling from one cell soils all cells and requires extensive cleaning
Solution Approach 1:
The patent transitions from batch processing of multiple cells together to individual cell processing. Each cell is filled separately using the ultrasonic acceleration method, which enables such rapid filling that the cell can be sealed immediately after infiltration. This segmentation eliminates cross-contamination between cells while the ultrasonic technique keeps individual filling times short enough to maintain productivity.
3Speed
If vacuum environment is used to aid electrolyte infiltration, then infiltration speed improves, but energy consumption increases significantly
Solution Approach 1:
The patent replaces the energy-intensive vacuum environment with ultrasonic mechanical vibration to accelerate electrolyte infiltration. The ultrasonic transducer directly applies mechanical energy to the cell, creating cavitation and enhancing capillary action without requiring vacuum conditions. This dramatically reduces energy consumption while maintaining or improving infiltration speed.
4Manufacturing precision
If multiple filling steps with vacuum wetting periods are used, then complete electrode wetting is achieved, but production productivity decreases
Solution Approach 1:
The patent uses ultrasonic vibration during the filling process to ensure complete and uniform electrolyte distribution throughout the porous electrodes. The mechanical energy penetrates deep into the electrode structure, forcing electrolyte into all voids and ensuring thorough wetting in a single rapid step, eliminating the need for multiple filling cycles and vacuum wetting periods.
Solution Approach 2:
The ultrasonic filling process maintains continuous useful action throughout the infiltration period. The vibration is applied continuously during the brief filling operation, ensuring that electrolyte keeps penetrating the electrodes without interruption or stagnation, achieving complete wetting in one continuous process rather than intermittent steps.
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 system significantly reduces the time required for electrolyte infiltration, preventing parasitic reactions and achieving full wetting of the electrodes, thus enhancing the efficiency and speed of the battery cell filling process.
Implementation Method 1
A system utilizing a transducer to generate a wave, positioned in conjunction with a battery cell to create a standing wave
Implementation Method 2
a transducer for generating a wave in response to an excitation signal
Data Source
AI summary
The present invention relates to a system a system for accelerating the infiltration of a liquid electrolyte in a battery cell, the system comprising: means for positioning the battery cell; a transducer for generating a wave in response to an excitation signal, a controller for controlling the transducer; wherein the transducer and the battery cell are positioned such that the battery cell sits in the direction of propagation; wherein the transducer and the battery cell are positioned such that a distance from the transducer to a surface of the battery cell, furthest away from the transducer, is equal to or larger than one fourth of the wavelength; wherein the controller is configured to bring the voltage and the current of the excitation signal in phase with one another. The present invention also relates to a method or accelerating the infiltration of a liquid electrolyte in a battery cell.