Vent Cap Assembly Catalyst Water Vapor Recombination

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Solution Overview

Problem

Existing battery vent caps are inefficient in recombining water vapor back into the battery, leading to frequent maintenance needs and reduced battery performance due to lower fluid levels.

Innovation Solution

A vent cap assembly with a cylindrical base and catalyst component that hydronates hydrogen and oxygen back into water, using bayonet tabs for secure fit and a flame arrestor to prevent sparks, along with a cap insert to stabilize the catalyst and facilitate water recombination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional vent caps are used to allow gas to escape freely, then water vapor can vent from the battery, but water is lost and maintenance frequency increases

Engineering Contradiction:

Improvebattery performanceVSAvoidwater loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent converts the harmful escape of water vapor into a beneficial process by capturing the vapor and recombining it back into liquid water that returns to the battery. The vent cap assembly transforms what was previously a loss (water vapor escaping) into a benefit (water recovery and return to battery), directly resolving the contradiction between venting gas and preventing water loss.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent implements a recovery system that captures water vapor that would otherwise be discarded through venting. The catalyst component recovers the water from the vapor phase and returns it to the battery, transforming a discarding process into a recovering process that eliminates water loss while maintaining proper venting function.

Inventive Principle:

Principle #34Discarding and recovering

2Loss of substance

If vent caps capture water vapor using plastic pellets or micro-porous discs, then water evaporation is minimized, but recombination efficiency is insufficient

Engineering Contradiction:

Improvewater evaporationVSAvoidwater recombination efficiency

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The patent fundamentally changes the mechanism from passive physical capture (plastic pellets or micro-porous discs) to active chemical recombination using a catalyst component. This parameter change in the recombination mechanism enables significantly higher efficiency, achieving 90-95% water vapor recombination compared to the insufficient efficiency of previous methods.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical/physical capture system (plastic pellets or micro-porous discs) with a chemical system using a catalyst component that facilitates the recombination of hydrogen and oxygen from water vapor back into liquid water. This substitution enables much higher recombination efficiency while maintaining the venting function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If more aggressive water capture methods are used, then water recombination efficiency increases, but device complexity increases

Engineering Contradiction:

Improvewater recombination efficiencyVSAvoidvent cap structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into a single integrated vent cap assembly: venting gas, capturing water vapor, catalyzing recombination, and returning liquid water to the battery. By combining these functions in one compact device, the patent achieves high recombination efficiency without proportionally increasing complexity, as the components work together in a unified system rather than separate assemblies.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The vent cap assembly performs multiple functions simultaneously: it acts as a vent for gas escape, a capture device for water vapor, a catalyst support for recombination, and a return system for liquid water. This multi-functionality achieves high water recombination efficiency while avoiding the complexity of separate dedicated systems for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 vent cap assembly effectively captures and recombines 90-95% of water vapor, significantly prolonging the time between maintenance intervals and maintaining battery performance.

Implementation Method 1

A catalyst component is received in the base and is configured to hydronate hydrogen and oxygen to water

Methodology Applied

Scientific EffectHydronation: Chemical Bonding

Implementation Method 2

The vent caps include a plurality of plastic pellets to condense the water vapor and redirect or recombine the water back into the battery

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS10601010B2Recombination vent cap

Publication Date: 2020.03.24 DOYLE MICHAEL A

AI summary

A vent cap assembly for recombining water for a battery includes a cylindrical base having an upper portion and a lower portion. The lower portion configured to be inserted into a vent port. A cap encloses the cylindrical base. A catalyst component is received in the base configured to hydronate hydrogen and oxygen to water.