Zinc-Air Battery Electrolyte Circulation for Dendrite Prevention

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Solution Overview

Problem

Conventional zinc-air secondary batteries face issues with potassium hydroxide deposition in the air positive electrode and the formation of zinc dendrites due to uneven electrolyte concentration, leading to performance deterioration.

Innovation Solution

A zinc-air secondary battery system that includes a zinc-air battery array, an external electrolyte tank, and an electrolyte transport part to circulate the electrolyte, maintaining optimal concentration by arranging the electrolyte outflow portion higher than the inflow portion, and using non-woven fibers as separators to prevent potassium ion migration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a slurry-type electrolyte is used in a zinc-air secondary battery, then the battery can operate by transferring electrons generated when zinc reacts with oxygen, but the concentration of potassium hydroxide increases due to water consumption during discharge, causing potassium hydroxide deposition in the air positive electrode part and performance deterioration

Engineering Contradiction:
Improvedischarge capacityVSAvoidelectrolyte concentration stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent employs a dynamic electrolyte management system where the electrolyte concentration is actively maintained through a controlled water addition mechanism. The water content in the electrolyte is regulated to prevent excessive concentration increase during discharge, thereby avoiding potassium hydroxide deposition while maintaining adequate ionic conductivity for sustained productivity.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent modifies the electrolyte composition parameters by controlling the water-to-potassium hydroxide ratio and adjusting the initial electrolyte concentration. By optimizing these parameters and dynamically adjusting water content during operation, the system maintains stable electrolyte concentration despite water consumption during discharge, preventing both deposition issues and concentration instability.

Inventive Principle:
Principle #35Parameter changes

2Productivity

If water is consumed in the electrolyte during discharge, then the electrochemical reaction proceeds, but the potassium hydroxide concentration increases rapidly causing zinc dendrites to form in the zinc gel negative electrode part and performance deterioration

Engineering Contradiction:
Improvedischarge rateVSAvoidelectrolyte composition uniformity
Core Design Contradiction:
ProductivityVSStability of the object's composition

Solution Approach 1:

The patent implements a feedback control mechanism where the electrolyte composition is monitored during discharge operation. Based on the measured water consumption and concentration changes, the system adjusts water addition rates to maintain uniform electrolyte composition, preventing localized high concentration zones that would promote zinc dendrite formation while sustaining adequate discharge rates.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent applies preliminary action by pre-distributing water or dilute electrolyte solution to the electrolyte system before discharge begins. This preliminary adjustment ensures uniform electrolyte composition from the start of discharge, preventing rapid concentration changes and dendrite formation during the discharge process while maintaining productivity.

Inventive Principle:
Principle #10Preliminary action

3Reliability

If the electrolyte concentration is not maintained, then potassium hydroxide deposits in the air positive electrode part destroying the electrode, but maintaining proper concentration requires an electrolyte circulation system

Engineering Contradiction:
Improveelectrode integrityVSAvoidelectrolyte management system
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a self-service approach where the electrolyte system automatically manages its own concentration through a simple water addition mechanism triggered by the discharge process itself. The system uses the discharge current or voltage as a trigger to add water, eliminating the need for complex external monitoring and control systems while maintaining electrode integrity through proper concentration management.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent introduces water or dilute electrolyte solution as an intermediary substance to manage the concentration balance. This intermediary is added in controlled amounts to counteract water consumption during discharge, preventing potassium hydroxide deposition on the air positive electrode without requiring complex circulation systems, thus maintaining electrode integrity with minimal added complexity.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 effectively maintains electrolyte concentration, preventing potassium hydroxide deposition and zinc dendrite formation, while also enhancing oxygen supply and discharge efficiency, resulting in improved charging performance and sustained high output voltage.

Implementation Method 1

an electrolyte transport part configured to flow the electrolyte from the external electrolyte tank into the zinc gel negative electrode part in each of the zinc-air battery cells so that the electrolyte within the external electrolyte tank and the electrolyte within the zinc gel electrode part are circulated

Methodology Applied
Scientific EffectFluid flow:

Implementation Method 2

a separation membrane (separator) is arranged between the air positive electrode part and the zinc gel negative electrode part. The separator is a member that prevents an internal short circuit due to direct contact between the air positive electrode part and the zinc gel negative electrode part

Methodology Applied
Scientific EffectIon separation: Semipermeable Membrane

Implementation Method 3

The zinc-air secondary battery operates by transferring electrons generated when zinc contained in the electrolyte reacts with oxygen in the air and changes to zinc oxide

Methodology Applied
Scientific EffectElectrochemical reaction: Redox Reactions

Implementation Method 4

during charging, oxygen present in the zinc oxide is separated and discharged and returns to original zinc

Methodology Applied
Scientific EffectOxygen separation: Electrolysis

Data Source

PatentUS20250087788A1Zinc-air secondary battery system
Publication Date: 2025.03.13 ZINC TECHNOLOGIES INC
  • US20250087788A1 patent drawing
  • US20250087788A1 patent drawing
  • US20250087788A1 patent drawing

AI summary

A zinc-air secondary battery system of the present invention includes a zinc-air battery array formed by connecting a plurality of zinc-air battery cells each having an air positive electrode part, a separator and a zinc gel negative electrode part containing an electrolyte inside a rectangular case; an external electrolyte tank for storing the electrolyte; and an electrolyte transport part configured to flow the electrolyte from the external electrolyte tank into the zinc gel negative electrode part in each of the zinc-air battery cells so that the electrolyte within the external electrolyte tank and the electrolyte within the zinc gel electrode part are circulated. The external electrolyte tank and the case are provided with gas vent holes. The case is provided with an electrolyte inflow portion that allows the electrolyte from the external electrolyte tank to flow into the zinc gel negative electrode part and an electrolyte outflow portion that allows the electrolyte inside the zinc gel negative electrode part to flow out to the outside, and the electrolyte outflow portion is arranged at a position higher than a position where the electrolyte inflow portion is provided.