DESC:TECHNICAL FIELD
The present disclosure relates generally to battery technology and more specifically, to a battery device (e.g., a flooded monopolar Zinc-based battery device or a static monopolar ZincGel battery) with two-part casing to compress cell layers and a method for assembling the battery device.
BACKGROUND
Generally, flooded batteries are widely used in various stationary as well as non-stationary applications, such as portable electronic devices, electric vehicles, and grid energy storage systems due to their long life and high charging capabilities. A flooded battery may include a liquid electrolyte used to trigger a chemical reaction for the generation and transmission of an electric current across a set of cell layers. Such cell layers are generally housed in a pouch to provide structural support and protection, such as by sealing a top side of the pouch through adhesives, and the like. However, the conventional flooded batteries have various drawbacks, such as quick deterioration of battery components due to toxic and flammable electrolytes, high manufacturing cost, difficulty in repair and maintenance of the flooded batteries, issue of high weight, and complex component assembly and manufacturing processes. Conventionally, the pouches (or containers) are sealed through adhesives that may react with the electrolyte, thereby interfering with battery chemistry and may result in deterioration of battery's health over time. Furthermore, the use of adhesives and other sealing frames may cause electric current leakage that leads to depletion of battery life. As a result, there exists a technical problem of how to reduce complexity in assembly of battery components and at the same time avoid use of glue or sealants without any compromise in handling of electrolyte leakage and current leakage in a cost-effective manner.
Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional battery devices and the methods of assembling the same.
SUMMARY
The present disclosure provides a battery device (e.g., a flooded monopolar Zinc-based battery device or a static monopolar ZincGel battery) with a two-part casing to compress cell layers and a method for assembling the battery device. The present disclosure provides a solution to the existing problem of how to reduce complexity in assembly of battery components and at the same time avoid use of glue or sealants without any compromise in handling of electrolyte leakage and current leakage. An objective of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art and provides an improved battery device with a two-part casing to compress cell layers and a method for assembling the battery device.
One or more objectives of the present disclosure are achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
In one aspect, the present disclosure provides a battery device that includes a plurality of cell layers comprising a set of electrode layers, a set of separator layers, and a set of current collector layers arranged in a predefined sequence and a two-part casing to accommodate the plurality of cell layers. Moreover, the first part and a second part of the two-part casing are structurally complementary to each other, and the first part comprises a first outer rib projection with a male energy line and the second part comprises a second outer rib projection with a female energy line. Furthermore, the first outer rib projection is joined with the second outer rib projection via the complementary male energy line and the female energy to seal the two-part casing. Furthermore, during the sealing of the first part with the second part of the two-part casing, the plurality of cell layers is compressed in a defined pressure range between the first part and the second part such that a direct contact is established between each current collector layer of the set of current collector layers and corresponding electrode layers of the set of electrode layers.
The disclosed battery device includes an improved battery casing that is used intelligently to compress the plurality of cell layers to ensure a direct contact between each current collector layer and corresponding electrode layer that improves the overall performance and efficiency of the battery device. The battery device includes the two-part casing that is structurally complementary to each other and can be manufactured from a single die, which makes the battery device more cost-effective and easier to assemble.
Typically, conventional battery devices use pouches or encapsulation systems to enclose the plurality of cell layers that are bounded such as using adhesives with sealing blocks due to which the overall cost and weight of the conventional battery device increases. Moreover, the adhesives that are used in the conventional battery devices to bind the sealing blocks and conventional cell layers together react with the electrolyte that reduces the overall life span of the conventional battery devices, such as by adversely affecting battery chemistry of the conventional battery devices. Additionally, the adhesives that are used to bind the conventional battery devices melt due to high battery device temperature, which leads to the leakage of the electric current.
Beneficially as compared to the conventional batteries, the two-part casing allows a more precise and simplified assembly of battery components and thereby reduces complexity in manufacturing process of the battery device. The two-part casing of the battery device includes complementary male and female energy lines to seal both the parts (i.e., a first part and a second part of the battery device) to provide a secure and reliable joining of the two-parts to prevent any electric current leakage and also ensure the safe operation as well as the integrity of the battery device with low-cost and increased mechanical strength. Additionally, the use of the first outer rib projection and the second outer rib projection to join the first part with the second part of the casing is beneficial to create a more secure and stable seal, reducing the risk of failure or leakage that further provide to a more consistent and reliable manufacturing process, which increases the quality and performance of the battery device. Furthermore, the battery device is assembled by the compression of the plurality of cell layers in a defined pressure range between the two parts (i.e., the first part and the second part) of the two-part casing to ensure the direct contact between each current collector layer and corresponding electrode layer that improves the overall performance and efficiency of the battery device, such as by allowing free flow of electrons from one electrode to another. In addition, the plurality of cell layers, such as an anode layer, a cathode layer, and a current collector layer is porous in nature due to which the overall conductivity of the battery device increases. Hence, the overall battery health of the battery device is improved efficiently and reliably with reduced manufacturing costs.
In an implementation, the set of current collector layers comprises a plurality of cathode current collector layers, and each cathode current collector layer is sandwiched between two corresponding cathode layers disposed on either side of each cathode current collector layer.
The placement of the cathode layers on either side of the cathode current collector layer makes the battery device a monopolar battery device that allows an efficient and optimized transfer of the electric current from the cathode current collector to the external device or load that is connected to the battery device.
In a further implementation, the set of electrode layers comprises a plurality of anode layers and a plurality of cathode layers, and a thickness of each cathode layer is greater than each anode layer.
Advantageously, the thickness of the plurality of the cathode layer increases the overall energy density and the battery life of the battery device.
In a further implementation, a width of a stack of the plurality of cell layers before compression is greater than a width of the two-part casing.
In a further implementation, the battery device is a zinc-based monopolar battery in which the plurality of cell layers are compressed devoid of any glue, any sealing blocks, or any frames to hold each current collector layer of the set of current collector layers.
In a further implementation, the defined pressure range in which the plurality of cell layers are compressed between the first part and the second part is in a range of 20-80 kg/cm2.
In a further implementation, the defined pressure range in which the plurality of cell layers is compressed between the first part and the second part is in a range of 40-50 kg/cm2.
Advantageously, the defined pressure range (or a range of compression percentages) allows balanced compression (not extremely high nor low) of the plurality of cell layers to ensure proper electrical contact between each current collector layer and corresponding electrode layer that improves the overall performance and efficiency of the battery device. This also provides flexibility in the manufacturing process while still ensuring that the battery device is of sufficient density and quality.
In a further implementation, the two-part casing is in a half-and-half configuration. The half-and-half configuration of the two-part casing provides a structural integrity to the battery device that allows a simplified assembly of battery components, for example, the plurality of cell layers can be placed and compressed at the time of joining the two-part casing in the battery device.
In another aspect, the present disclosure provides a method for assembling a battery device. The method includes arranging a plurality of cell layers comprising a set of electrode layers, a set of separator layers, and a set of current collector layers in a predefined sequence, placing a stack of the plurality of cell layers arranged in the predefined sequence on a first part of a two-part casing of the battery device, placing a second part of the two-part casing on top of the stack of the plurality of cell layers and the first part and sealing the first part with the second part of the two-part casing by compressing the stack of the plurality of cell layers at a defined pressure range within the first part and the second part such that a direct contact is established between each current collector layer of the set of current collector layers and corresponding electrode layers of the set of electrode layers. The sealing of the first part with the second part comprises joining a first outer rib projection of the first part with a second outer rib projection of the second part of the two-part casing. Further, the joining of the first outer rib projection with the second outer rib projection comprises heat sealing a male energy line provided on the first outer rib projection against a female energy line provided on the second outer rib projection to seal the two-part casing.
The method achieves all the advantages and technical effects of the battery device of the present disclosure. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims. Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 is a diagram that depicts an exploded view of a battery device, in accordance with an embodiment of the present disclosure;
FIGs. 2A and 2B are different diagrams that depict different perspective views of a first part and a second part of a two-part casing for a battery device, in accordance with an embodiment of the present disclosure;
FIGs. 2C and 2D are portions of a male energy line and a female energy line of a first part and a second part of a two-part casing for a battery device, in accordance with an embodiment of the present disclosure;
FIG. 3A is a diagram that depicts a formation of a plurality of cell layers of a battery device, in accordance with an embodiment of the present disclosure;
FIG. 3B is a diagram that depicts a plurality of cell layers compressed in a two-part casing of a battery device, in accordance with an embodiment of the present disclosure;
FIG. 4A is a diagram that depicts an exploded view of a battery device, in accordance with an embodiment of the present disclosure;
FIG. 4B is a diagram that depicts a top view of a battery device, in accordance with an embodiment of the present disclosure;
FIG. 5 is a diagram that depicts a perspective view of a battery device, in accordance with an embodiment of the present disclosure; and
FIG. 6 is a flowchart of a method for assembling a battery device, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
FIG. 1 is a diagram that depicts an exploded view of a battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 1, there is shown an exploded view 100 of a battery device 102. The battery device 102 includes a plurality of cell layers 106, and a two-part casing, such as a first part 104A and a second part 104B.
The battery device 102 includes the plurality of cell layers 106 that further includes a set of electrode layers, a set of separator layers, and a set of current collector layers arranged in a predefined sequence. The set of electrode layers, such as a plurality of cathode layers and a plurality of anode layers are arranged along with the set of separator layers and the set of current collector layers to form a stack of the plurality of cell layers, as further shown and described in FIG. 3A. The plurality of cell layers is configured to provide an electric current to an external device or load ,which is attached to the battery device 102. In accordance with an embodiment, the set of electrode layers includes a plurality of anode layers and a plurality of cathode layers and a thickness of each cathode layer is greater than each anode layer, as further shown and described in FIG. 3A. Moreover, each of the plurality of anode layers and the plurality of cathode layers are made up of carbon sheets to conduct an electric current from one electrode layer to another electrode layer. In an implementation, the set of electrode layers is made up of carbon sheets with a high surface area in order to provide low conductivity. In another implementation, the set of electrode layers is made up of a carbon sheet with a low surface area in order to provide high conductivity without affecting the scope of the present disclosure. Additionally, the thickness of each of the cathode layer from the plurality of cathode layers is greater than the thickness of the each of the anode layer from the plurality of the anode layer that increases the energy density of the plurality of the cathode layer that allows the plurality of cathode layers to store more energy per unit of volume. Therefore, the thickness of the plurality of the cathode layer increases the overall energy density of the battery device 102.
In accordance with an embodiment, the set of current collector layers includes a plurality of cathode current collector layers and each cathode current collector layer is sandwiched between two corresponding cathode layers disposed on either side of each cathode current collector layer, as further shown and described in FIG. 3A. Each cathode current collector layer from the set of current collector layers is sandwiched between the two corresponding cathode layers to collect the electrical current that is collected by each of the corresponding cathode layers and further transmits the collected electric current to an external device that is attached with the battery device 102. For example, a first cathode current collector layer is sandwiched between a first cathode layer and a second cathode layer. As a result, the disposition of the cathode layer on either side of the cathode current collector layer allows an efficient and optimized transfer of the electric current from the cathode current collector to the external device that is connected to the battery device 102. Similarly, in accordance with another embodiment, the set of current collector layers includes a plurality of anode current collector layers, and each anode current collector layer is sandwiched between two anode layers disposed on either side of each anode current collector layer. For example, a first anode current collector layer is sandwiched between a first anode layer and a second anode layer. An exemplary implementation of the arrangement of the set of the current collector layers that includes the plurality of cathode current collector layers and the plurality of anode current collector layers is further shown and described in detail in FIG. 3A. As a result, the plurality of anode current collector layers is in direct contact with the anode layers that are required for the flow of the electric current.
Furthermore, the battery device 102 includes a two-part casing to accommodate the plurality of cell layers 106. Moreover, the two-part casing includes two different parts, such as the first part 104A and the second part 104B in which the plurality of cell layers 106 that includes the set of electrode layers, the set of separator layers, and the set of current collector layers are accommodated and arranged in the predefined sequence. In an implementation, the two-part casing is made up of HDPE polymer that improves the overall battery chemistry of the battery device 102, as the HPDPE polymer does not react with the electrolyte (i.e., a zinc-based electrolyte) that is filled in the battery device 102. Moreover, the first part 104A and the second part 104B of the two-part casing are structurally complementary to each other. The first part 104A and the second part 104B of the two-part casing are designed in such a manner that both the parts fit together so that each part of the two-part casing (i.e., the first part 104A and the second part 104B) covers a half of the surface area of the battery device 102. In addition, the first part 104A and the second part 104B of the two-part casing are structurally complementary (i.e., with a mirror image) of each other. Therefore, a single die is required for the manufacturing of both the parts (i.e., the first part 104A and the second part 104B) of the two-part casing. In accordance with an embodiment, the two-part casing is in a half-and-half configuration. An exemplary implementation of the half-and-half configuration of the two-part casing is further shown and described in detail in FIGs. 2A and 2B. The half-and-half configuration of the two-part casing provides a structural integrity to the battery device 102 that allows an easy assembling of the two-part casing of the battery device 102.
Furthermore, the first part 104A includes a first outer rib projection with a male energy line and the second part 104B includes a second outer rib projection with a female energy line. Moreover, the first outer rib projection is joined with the second outer rib projection via the complementary male energy line and the female energy to seal the two-part casing. The first outer rib projection with the male energy line and the second outer rib projection with the female energy lines are interlocked with each other to ensure secure and tight binding of the first part 104A and the second part 104B of the two-part casing. As a result, a leakproof two-part casing is manufactured that is used to prevent the leakage of the electric current with an improved life span of the battery device 102. In accordance with an embodiment, the battery device 102 is a zinc-based monopolar battery in which the plurality of cell layers 106 are compressed devoid of any glue, any sealing blocks, or any frames to hold each current collector layer of the set of current collector layers. The glue used to hold each current collector layer of the set of current collector layers is used in the conventional battery devices. However, the glue reacts with the electrolyte that is filled in the battery device 102, which adversely affects the battery chemistry of the battery device 102, and thus, the lifespan of the battery device 102 is reduced. Additionally, the use of the sealing blocks or any frames that are used to hold each current collector layer of the set of current collector layers increases the manufacturing cost and the overall weight of the battery device 102. Thus, the zinc-based monopolar battery of the present disclosure provides the plurality of cell layers 106 that are compressed devoid of any glue, any sealing blocks, or any frames to hold each current collector layer of the set of current collector layers. Therefore, the overall battery performance of the battery device 102 is improved and the cost as well as the weight of the battery device 102 are reduced. Furthermore, during the sealing of the first part with the second part of the two-part casing, the plurality of cell layers 106 is compressed in a defined pressure range between the first part and the second part such that a direct contact is established between each current collector layer of the set of current collector layers and corresponding electrode layers of the set of electrode layers. The compression of the two-part casing (i.e., the first part 104A and the second part 104B) and the plurality of cell layers 106 ensures the establishment of the direct contact between each of the current collector layers of the set of the current collector layers and the corresponding electrode layers of the set of the electrode layers that are required for the flow of the electrons. As a result, the electrochemical reactions and a free flow of electrons from one electrode to another that are necessary for the distribution of the electrical current in the battery device 102 are performed efficiently and effectively. In accordance with an embodiment, the defined pressure range in which the plurality of cell layers 106 is compressed between the first part and the second part is in a range of 20-80 kg/cm2. The compression of the first part, the second part, and the plurality of the cell layers 106 in the range of the 20-80 kg/cm2 reduce the overall surface area of the battery device 102 as shown and described in detail in FIG. 3B. In an example, the plurality of cell layers 106 are compressed between the first part 104A and the second part 104B with the pressure of 20kg/cm2. In another example, the plurality of cell layers 106 is compressed between the first part 104A and the second part 104B with the pressure of 80kg/cm2. Similarly, the plurality of cell layers 106 is compressed between the first part 104A and the second part 104B with the pressure of 50kg/cm2 without limiting the scope of the present disclosure. In accordance with another embodiment, the defined pressure range in which the plurality of cell layers 106 is compressed between the first part 104A and the second part 104B is in a range of 40-50 kg/cm2. As a result, the overall efficiency and stability of the battery device 102 is improved.
The disclosed battery device 102 provides an improved battery casing that improves the overall battery health of the battery device 102 in a cost-effective manner. The battery device 102 includes the two-part casing that is structurally complementary to each other and can be manufactured from a single die, which makes the battery device 102 more cost-effective and easy to assemble and disassemble. However, the conventional battery devices use pouches or encapsulation systems to enclose the plurality of cell layers 106 that are bounded such as using adhesives with sealing blocks due to which the overall cost and weight of the conventional battery device increase. Moreover, the adhesives that are used in the conventional battery devices to bind the sealing blocks and the plurality of cell layers 106 together react with the electrolyte that reduces the overall life span of the conventional battery devices, such as by adversely affecting battery chemistry of the conventional battery devices. Additionally, the adhesives that are used to bind the conventional battery devices melt due to high battery device temperature that leads to the leakage of the electric current. Thus, the two-part casing is used along with the complementary male and female energy lines to seal both the parts (i.e., a first part and a second part of the battery device) to provide a secure and reliable connection to prevent any electric current leakage and also ensure the safe operation of the battery device 102 with low-cost and increased mechanical strength. Furthermore, the battery device 102 is assembled by the compression of the plurality of cell layers in a defined pressure range between the two parts (i.e., the first part 104A and the second part 104B) of the two-part casing to ensure a direct contact between each current collector layer and corresponding electrode layer that improves the overall performance and efficiency of the battery device 102, such as by allowing free flow of electrons from one electrode to another. In addition, the plurality of cell layers 106, such as an anode layer, a cathode layer, and a current collector layer is porous in nature due to which the overall conductivity of the battery device 102 increases. Hence, the overall battery health of the battery device 102 is improved efficiently and reliably with reduced manufacturing costs.
FIGs. 2A and 2B are different diagrams that depict perspective views of a first part and a second part of a two-part casing for a battery device, in accordance with an embodiment of the present disclosure. FIGs. 2A and 2B are described in conjunction with elements from FIGs. 1. With reference to FIG. 2A, there is shown a diagram 200A that depicts a perspective view of the first part 104A of a two-part casing for the battery device 102 (of FIG. 1). With reference to FIG. 2B, there is shown a diagram 200B that depicts a perspective view of the second part 104B of the two-part casing for the battery device 102 (of FIG. 1).
The first part 104A and the second part 104B of the two-part casing are structurally complementary to each other, as shown in FIGs. 2A and 2B. In accordance with an embodiment, the two-part casing of the battery device 102 is in a half-and-half configuration. In other words, an area of the first part 104A is equal to the area of the second part 104B. Moreover, as the first part 104A and the second part 104B are structurally complementary, and in the half-and-half configuration, therefore, a single die can be used for manufacturing the first part 104A and the second part 104B with reduced manufacturing time and cost as compared to manufacturing two separate dies for each part of the two-part casing. Additionally, using a single die ensures a consistent and accurate shape for both parts of the two-part casing, which is important for ensuring the proper fit and functioning of the battery device 102. Optionally, the two-part casing of the battery device 102 can include other types of configurations, such as a ratio of 60-40 or a ratio of 70-30, another alternative ratio of the two-part casing may be used to achieve different design goals or functional requirements without limiting the scope of the present disclosure.
There is further shown that the first part 104A includes a first outer rib projection 202A with a male energy line 204A as shown in FIG. 2A. Moreover, the second part 104B includes a second outer rib projection 202B with a female energy line 204B, which is complementary to the male energy line 204A.
Moreover, the first outer rib projection 202A is joined with the second outer rib projection 202B via the male energy line 204A and the female energy line 204B to seal the two-part casing. Beneficially, the two-part casing of the battery device 102 can be designed and fabricated with a low-cost production, as compared to the conventional battery devices. In addition, the two-part casing is made up of HDPE polymer, which is flexible and can be easily attached with a plastic cell holder by using heat sealing. Furthermore, the mechanical strength of the two-part casing improved due to which each of the first part 104A and the second part 104B are efficient and reliable for a stable battery chemical environment in the battery device 102.
In an implementation, the first part 104A further includes a first extended portion 206A, a second extended portion 206B, and a first shaft 208. Similarly, the second part 104B also includes a third extended portion 206C, a fourth extended portion 206D, and a second shaft 210. Each of the first extended portion 206A, the second extended portion 206B, and the first shaft 208, is designed and manufactured through the moulding process of the first part 104A. Similarly, each of the third extended portion 206C, the fourth extended portion 206D, and the second shaft 210 are designed and manufactured through the moulding process of the second part 104B, such as by using a die. In an example, the shape and size of each the first extended portion 206A, the second extended portion 206B, the third extended portion 206C, the fourth extended portion 206D, the first shaft 208, and the second shaft 210 may vary without limiting the scope of the present disclosure. Furthermore, during the sealing of the first part 104A with the second part 104B of the two-part casing, the first extended portion 206A unites with the third extended portion 206C, which results in the formation of a passageway through which a terminal (e.g., a positive terminal) can be passed for further connectivity (e.g., for charging and discharging of the battery device 102). Similarly, the second extended portion 206B unit with the fourth extended portion 206D, which results in the formation of another passageway through which another terminal (e.g., a negative terminal) can be passed for further connectivity (e.g., for charging and discharging of the battery device 102). In addition, each of the first shaft 208 (of FIG. 2A) or the second shaft 210 (of FIG. 2B) are hollow structures, such as either the first shaft 208 or the second shaft 210 can be used to fill an electrolyte in the battery device 102. In an example, both the first shaft 208 and the second shaft 210 can be used to pour the electrolyte within the battery device 102.
FIG. 2C is a diagram that depicts a portion of a male energy of a first part and a of a two-part casing for a battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 2C, there is shown a portion of the male energy line 204A of the first outer rib projection (as shown in FIG. 2A) of the first part of the two-part casing for the battery device 102. The male energy line 204A is a protrusion disposed along peripheral portion of the first outer rib projection of the battery device 102.
FIG. 2D is a diagram that depicts a portion of a female energy of a second part of a two-part casing for a battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 2D, there is shown a portion of the female energy line 204B of the second outer rib projection (as shown in FIG. 2B) of the second part of the two-part casing for the battery device 102. In an implementation, the female energy line 204B is a trough configured along peripheral portion of the first outer rib projection of the battery device 102. to accommodate the male energy line 204A.
In an implementation, the female energy line 204B is a negative replica of the male energy line 204A. In an example, during assembly of the two-part casing for the battery device 102, the male energy line 204A of the first part of the two part casing is inserted in the female energy line 204B of the second part of the two part casing so that the first part 104A and the second part 104B are structurally complemented to each other. The male energy line 204A and the female energy line 204B are beneficial to firmly join the two part casing of the battery device 102.
FIG. 3A is a diagram that depicts a formation of a plurality of cell layers of a battery device, in accordance with an embodiment of the present disclosure. FIG. 3A is described in conjunction with elements from FIGs. 1, 2A and 2B. With reference to FIG. 3A, there is shown a diagram 300A that depicts the formation of the plurality of cell layers 106 of the battery device 102.
In accordance with an embodiment, the set of current collector layers of the plurality of cell layers 106 includes a plurality of cathode current collector layers 304A-to-304N. In such an embodiment, the set of current collector layers further includes a plurality of anode current collector layers 312A-to-312N. In such an embodiment, the set of electrode layers further includes a plurality of cathode layers 306A-to-306N and a plurality of anode layers 310A-to-310N. In addition, each cell layer from the plurality of cell layers 106 includes a cathode current collector layer, a cathode layer, a separator, an anode layer, and an anode current collector layer. For example, a first stack 302 (or a cell layer) of the plurality of cell layers 106 includes a first cathode current collector layer 304A, a first cathode layer 306A, a first separator layer 308A, a first anode layer 310A, and a first anode current collector layer 312A. Moreover, the plurality of cell layers 106 of the battery device 102 further includes a set of electrode layers, a set of separator layers 308A-to-308N, and a set of current collector layers that are arranged in a predefined sequence. In accordance with an embodiment, the predefined sequence is the first cathode current collector layer 304A, the first cathode layer 306A, the first separator layer 308A, the first anode layer 310A, the first anode current collector layer 312A, a second anode layer 310B, a second separator layer 308B, a second cathode layer 306B, a second cathode current collector layer 304B, a third cathode layer 306C, a third separator layer 308C, a third anode layer 310C, a second anode current collector layer 312B, and so on, as shown in FIG. 3A. The predefined sequence is repeated up to Nth cathode layer 306N, Nth separator layer 308N, Nth anode layer 310N, and Nth anode current collector layer 312N. As a result, a second stack of the plurality of cell layers 106 are formed, and so on up to an Nth stack of the plurality of cell layers 106. Furthermore, a first width (w1) is formed for the plurality of cell layers 106 as a consequence of the process, as shown in FIG. 3A.
In an implementation, each anode current collector layer is sandwiched between two anode layers disposed on either side of each anode current collector layer. For example, the first anode current collector layer 312A of the first stack 302 is in contact with the second anode layer 310B. As a result, the first anode current collector layer 312A of the first stack 302 is sandwiched between two anode layers disposed on either side of each anode current collector layer, such as sandwiched between the first anode layer 310A and the second anode layer 310B, as shown in FIG. 3A. In such an implementation, each cathode current collector layer is sandwiched between two corresponding cathode layers disposed on either side of each cathode current collector layer. For example, the second cathode current collector layer 304B is in contact with a third cathode layer 306C. As a result, the second cathode current collector layer 304B is sandwiched between two corresponding cathode layers disposed on either side of each cathode current collector layer, such as between the second cathode layer 306B and the third cathode layer 306C. Similarly, subsequent layers can be arranged, which results in the formation of a monopolar (or flooded or static) battery cell layer, as shown in FIG. 3A.
In accordance with an embodiment, a thickness of each cathode layer is greater than each anode layer. In an example, each of the plurality of anode layers and the plurality of cathode layers are formed using a carbon-based material (e.g., graphite), such as the thickness of each cathode layer is greater than each anode layer. For example, a thickness (d1) of the first cathode layer 306A is greater than a thickness (d2) of the first anode layer 310A. As the thickness of each cathode layer is greater than each anode layer, therefore, each cathode layer can store more energy and can potentially result in higher energy density and longer battery life. In addition, due to the greater thickness, each cathode layer can absorb more heat during charging and discharging cycles while reducing the risk of thermal runaway. By virtue of adjusting the thickness of each cathode layer and each anode layer, the internal resistance of the set of electrode layers can be optimized, which further improves compatibility of the set of electrode layers with other components of the battery device 102, such as compatibility with the set of separator layers, the set of current collector layers separator as well as with the electrolyte (e.g., zinc-based electrolyte).
FIG. 3B is a diagram that depicts a plurality of cell layers compressed in a two-part casing of a battery device, in accordance with an embodiment of the present disclosure. FIG. 3B is described in conjunction with elements from FIGs. 1, 2A and 2B. With reference to FIG. 3B, there is shown a diagram 300B that depicts the plurality of cell layers 106 that are compressed in a two-part casing of the battery device 102.
The plurality of cell layers 106 are firstly arranged on the first part 104A of the two-part casing. Thereafter, the second part 104B (or the first part 104A) is arranged above the first part 104A, such as the plurality of cell layers 106 are sandwiched the first part 104A and the second part 104B. In an example, the plurality of cell layers 106 can be arranged on the second part 104B of the two-part casing, and then the first part 104A can be arranged above the second part 104B to cover the plurality of cell layers 106. As a result, the first outer rib projection 202A of the first part 104A is joined with the second outer rib projection 202B of the second part 104B via the complementary male energy line (i.e., the male energy line 204A) and the female energy line 204B to seal the two-part casing. Furthermore, during the sealing of the first part 104A with the second part 104B of the two-part casing, the plurality of cell layers 106 are compressed in a defined pressure range between the first part 104A and the second part 104B. Moreover, a direct contact is established between each current collector layer of the set of current collector layers and the corresponding electrode layers of the set of electrode layers. For example, the first cathode current collector layer 304A is in contact with the first cathode layer 306A, similarly, the first anode current collector layer 312A is in direct contact with the first anode layer 310A and also with the second anode layer 310B.
In such an embodiment, the defined pressure range in which the plurality of cell layers 106 are compressed between the first part 104A and the second part 104B is in a range of 20-80 kg/cm2. In accordance with another embodiment, the defined pressure range is in a range of 40-50 kg/cm2. In an example, a specific pressure range can be defined to be optimal for a particular type of system or application, potentially leading to improved performance of the battery device 102. Additionally, such a defined pressure range (or a range of compression percentages) allows for flexibility in the manufacturing process while still ensuring that the battery device 102 is of sufficient density and quality. In accordance with yet another embodiment, a stack of the plurality of cell layers 106 is compressed within a range of 20-70% of an original size of the stack of the plurality of cell layers 106. For example, a cell layer that includes the first stack 302 is compressed within the range of 20-70% of an original size of the first stack of the plurality of cell layers 106. Optionally, a specific pressure range can be defined to compress each stack (i.e., each cell layer) of the plurality of cell layers 106.
In accordance with an embodiment, the sealing of the first part 104A with the second part 104B includes joining the first outer rib projection 202A of the first part 104A with the second outer rib projection 202B of the second part 104B of the two-part casing. In such an embodiment, the joining of the first outer rib projection 202A with the second outer rib projection 202B includes heat sealing the male energy line 204A provided on the first outer rib projection 202A against the female energy line 204B provided on the second outer rib projection 202B to seal the two-part casing. Conventionally, pouches or encapsulation systems are used to enclose cell layers of conventional batteries, which increases the overall cost of the conventional batteries (e.g., lead acid batteries). The adhesives used to seal the pouches or encapsulation systems of the conventional batteries usually react with an electrolyte due to which the overall battery life of the conventional batteries reduces, such as by adversely affecting the overall battery chemistry of the conventional batteries. Additionally, the adhesives that are used to bind the conventional batteries sometimes melt in high battery temperature environment, which leads to an electric current leakage, and may cause health issues to a user. Beneficially as compared to the conventional batteries, the two-part casing allows a more precise and controlled manufacturing process of the battery device 102. The use of heat sealing the male and female energy lines to seal the casing is a reliable and effective method, which may help to ensure the integrity of the battery device 102 during use. Additionally, the use of the first outer rib projection 202A and the second outer rib projection 202B to join the first part 104A with the second part 104B of the casing is beneficial to create a more secure and stable seal, reducing the risk of failure or leakage that further provide to a more consistent and reliable manufacturing process, which increases the quality and performance of the battery device 102.
By virtue of sealing the first part 104A with the second part 104B, a second width (w2) is formed for the battery device 102 as a consequence of the process. In accordance with an embodiment, the width of the stack of the plurality of cell layers 106 before compression is greater than the width of the two-part casing. In other words, the second width (w2) is lesser than the first width (w1), which indicates that the compression process used in the assembly of the two-part casing and plurality of cell layers 106 results in a tightly packed and more secure arrangement of the plurality of cell layers 106 within the two-part casing. Beneficially as compared to conventional approaches, the two-part casing of the present disclosure prevents movement or damage to the plurality of cell layers 106 during use and transportation, potentially increasing the longevity and performance of the battery device 102.
In accordance with an embodiment, the battery device 102 is a zinc-based monopolar battery in which the plurality of cell layers 106 are compressed devoid of any glue, any sealing blocks, or any frames to hold each current collector layer of the set of current collector layers. In the absence of any glue, any sealing blocks, or any frames in the compressed plurality of cell layers 106 may simplify the manufacturing process of the battery device 102 and reduce production costs. This may also result in a lighter and more compact battery design, which could be advantageous in certain applications where weight and size are important considerations. Additionally, the lack of these components may reduce the risk of failure due to delamination or other mechanical stresses, potentially increasing the reliability and safety of the battery device 102.
FIG. 4A is a diagram that depicts an exploded view of a battery device, in accordance with an embodiment of the present disclosure. FIG. 4A is described in conjunction with elements from FIGs. 1, 2A, 2B, 3A and 3B. With reference to FIG. 4, there is shown an exploded view 400A of the two-part casing for the battery device 102 (of FIG. 1) along with the plurality of cell layers 106 (of FIG. 1).
In an implementation, the battery device 102 includes the plurality of cell layers 106, the two-part casing, such as the first part 104A and the second part 104B. The first part 104A further includes the first extended portion 206A, the second extended portion 206B, and the first shaft 208, as previously shown and described in FIG. 2A. Similarly, the second part 104B also includes the third extended portion 206C, the fourth extended portion 206D, and the second shaft 210, as previously shown and described in FIG. 2A. Furthermore, a top cover 402 is also designed and manufactured, such as through a die to cover the two-part casing. Firstly, the first part 104A and the second part 104B are joined together and the plurality of cell layers 106 are compressed within the first part 104A and the second part 104B. Thereafter, the first part 104A and the second part 104B of the two-part casing are sealed together, such as using the heat-sealing process. Furthermore, the top cover 402 is sealed with the two-part casing to cover the top end of the two-part casing. Finally, an electrolyte filling cap 404, a first terminal 406A, and a second terminal 406B are placed at the top cover 402, which are sealed with the top cover 402 of the two-part casing. In an example, a fixed cap 408 is used to cover a shaft, such as either the first shaft 208 or the second shaft 210, which is not used to fill the electrolyte (e.g., the zinc-electrolyte). In an implementation, a zinc-electrolyte is filled in the battery device 102, such as through the electrolyte filling cap 404. Thus, various components of the battery device 102, such as the plurality of cell layers 106, the first part 104A, the second part 104B, the top cover 402, the electrolyte filling cap 404, the first terminal 406A, and the second terminal 406B are assembled together to form the battery device 102.
FIG. 4B is a diagram that depicts a top view of a battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 4B, there is shown a top view 400B of the two-part casing for the battery device 102 (of FIG. 1). The top view 400B of the battery casing includes an electrolyte filling cap 404 and a fixed cap 408 along with the first terminal 406A and the second terminal 406B.
In an implementation, the first part 104A further includes a first extended portion 206A, a second extended portion 206B, and a first shaft 208. Similarly, the second part 104B also includes a third extended portion 206C, a fourth extended portion 206D, and a second shaft 210. In addition, each of the first shaft 208 (of FIG. 2A) or the second shaft 210 (of FIG. 2B) are hollow structures, such as either the first shaft 208 or the second shaft 210 can be used to fill an electrolyte within the battery device 102. In an example, both the first shaft 208 and the second shaft 210 can be used to fill the electrolyte within the battery device 102, such as through the electrolyte filling cap 404. Moreover, the other shaft, such as either the first shaft 208 or the second shaft 210, which is not used to fill the electrolyte (e.g., the zinc-electrolyte) is covered through the fixed cap 408. The fixed cap 408 can also be further used to fill the electrolyte when the other shaft is not functioning. Furthermore, the first terminal 406A and the second terminal 406B are connected with the plurality of cell layers 106 to transmit and receive the electric current. In an example, either the first shaft 208 or the second shaft 210 that is covered through the fixed cap 408 is enclosed within the top cover 402, and the shaft such as either the first shaft 208 or the second shaft 210 that is covered through the electrolyte filling cap 404 is not enclosed within the top cover 402 of the battery device 102. Thus, the battery device 102 is assembled with reduced cost-efficiently and effectively.
FIG. 5 is a diagram that depicts a perspective view of a battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 5, there is shown a perspective view 500 of the battery device 102 (of FIG. 1). In an implementation, the perspective view 500 of the battery device 102 depicts the two-part casing that includes the first part 104A and the second part 104B along with the first terminal 406A, the second terminal 406B, and the electrolyte filling cap 404. Moreover, the battery device 102 provides an improved overall battery health at a reduced cost. The battery device 102 includes the two-part casing that is structurally complementary to each other. Both the first part 104A and the second part 104B can be manufactured from a single die, which makes the battery device 102 more cost-effective and easy to assemble and disassemble. Therefore, the two-part casing is used along with the complementary male and female energy lines for sealing to provide a secure and reliable connection that is further used to prevent any electric current leakage to ensure the safe operation of the battery device with low-cost and increased mechanical strength.
FIG. 6 is a flowchart of a method for assembling a battery device, in accordance with an embodiment of the present disclosure. FIG. 6 is described in conjunction with elements from FIGs. 1 to 5. With reference to FIG. 6, there is shown a method 600 for assembling the battery device 102 (of FIG. 1). The method 600 includes steps 602 to 608.
There is provided the method 600 for assembling the battery device 102 (of FIG. 1). At step 602, the method 600 includes arranging the plurality of cell layers 106 includes the set of electrode layers, the set of separator layers 308A-to-308N, and the set of current collector layers in a predefined sequence. The set of electrode layers, such as the plurality of cathode layers 306A-to-306N and the plurality of anode layers 310A-to-310N (of FIG. 3A) are arranged along with the set of separator layers 308A-to-308N and the set of current collector layers to form a stack of the plurality of cell layers 106 that is configured to provide an electric current to an external device, which is attached with the battery device 102. At step 604, the method 600 further includes placing a stack of the plurality of cell layers 106 arranged in the predefined sequence on the first part 104A of a two-part casing of the battery device 102. Moreover, the two-part casing includes two different parts, such as the first part 104A and the second part 104B in which the plurality of cell layers 106 that includes the set of electrode layers, the set of separator layers 308A-to-308N, and the set of current collector layers arranged in the predefined sequence are accommodated. At step 606, the method 600 further includes placing the second part 104B of the two-part casing on top of the stack of the plurality of cell layers and the first part 104A. The first part 104A and the second part 104B of the two-part casing are designed in such a manner that both the parts fit together so that each part of the two-part casing (i.e., the first part 104A and the second part 104B) covers a half of the surface area of the battery device 102. In addition, both the parts (i.e., the first part 104A and the second part 104B) of the two-part casing are mirrors of each other. Therefore, a single mould is required for the manufacturing of both the parts (i.e., the first part 104A and the second part 104B) of the two-part casing.
At step 608, the method 600 further includes sealing the first part 104A with the second part 104B of the two-part casing by compressing the stack of the plurality of cell layers 106 at a defined pressure range within the first part 104A and the second part 104B, such as a direct contact is established between each current collector layer of the set of current collector layers and corresponding electrode layers of the set of electrode layers. The compression of the two-part casing (i.e., the first part 104A and the second part 104B) and the plurality of cell layers 106 ensures the establishment of the direct contact between each of the current collector layers of the set of the current collector layers and the corresponding electrode layers of the set of the electrode layers that are required for the flow of the electrons. As a result, the electrochemical reactions and a free flow of electrons from one electrode to another that are necessary for the distribution of the electrical current in the battery device 102 is performed efficiently and effectively.
The sealing of the first part 104A with the second part 104B includes joining a first outer rib projection of the first part with a second outer rib projection of the second part 104B of the two-part casing. In such an embodiment, the joining of the first outer rib projection 202A with the second outer rib projection 202B includes heat sealing the male energy line 204A provided on the first outer rib projection 202A against the female energy line 204B provided on the second outer rib projection 202B to seal the two-part casing. Conventionally, pouches or encapsulation systems are used to enclose cell layers of conventional batteries, which increases the overall cost of the conventional batteries (e.g., in lead acid batteries). The adhesives used to seal the pouches or encapsulation systems of the conventional batteries usually react with an electrolyte due to which the overall battery life of the conventional batteries reduces, such as by adversely affecting the overall battery chemistry of the conventional batteries. Additionally, the adhesives that are used to bind the battery device sometime melt in high battery temperature environment, which leads to an electric current leakage, and may cause health issues to a user. Beneficially as compared to the conventional batteries, the two-part casing allows a more precise and controlled manufacturing process of the battery device 102. The joining of the first outer rib projection with the second outer rib projection comprises heat sealing a male energy line provided on the first outer rib projection against a female energy line provided on the second outer rib projection to seal the two-part casing. The use of heat sealing the male and female energy lines to seal the casing is a reliable and effective method, which may help to ensure the integrity of the battery device 102 during use. Additionally, the use of the first outer rib projection 202A and the second outer rib projection 202B to join the first part 104A with the second part 104B of the casing is beneficial to create a more secure and stable seal, reducing the risk of failure or leakage that further provide to a more consistent and reliable manufacturing process, which increases the quality and performance of the battery device 102.
The disclosed method 600 is used to improve the overall battery health at a reduced cost. The battery device includes the two-part casing that is structurally complementary to each other. Both the parts can be manufactured from a single die, which makes the battery device more cost-effective and easier to assemble and disassemble. Therefore, the two-part casing is used along with the complementary male and female energy lines for sealing to provide a secure and reliable connection that is further used to prevent any electric current leakage to ensure the safe operation of the battery device with low-cost and increased mechanical strength. The method 600 is used for assembling the battery device 102 by the compression of the plurality of cell layers 106 in a defined pressure range between the two parts (i.e., the first part 104A and the second part 104B) of the two-part casing to ensure a direct contact between each current collector layer and corresponding electrode layer that further improves the overall performance and efficiency of the battery device 102. In addition, the plurality of cell layers 106, such as an anode layer, a cathode layer, and a current collector layer is porous in nature due to which the overall conductivity of the battery device increases. Hence, the method 600 provides an improved overall battery health efficiently and reliably with reduced manufacturing costs.
The steps 602 to 608 are only illustrative, and other alternatives can also be provided where one or more steps are added, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.
,CLAIMS:CLAIMS
We Claim:
1. A battery device (102), comprising:
a plurality of cell layers (106) comprising a set of electrode layers, a set of separator layers (308A-to-308N), and a set of current collector layers arranged in a predefined sequence; and
a two-part casing to accommodate the plurality of cell layers (106),
wherein a first part (104A) and a second part (104B) of the two-part casing are structurally complementary to each other,
and wherein the first part (104A) comprises a first outer rib projection (202A) with a male energy line (204A) and the second part (104B) comprises a second outer rib projection (202B) with a female energy line (204B),
and wherein the first outer rib projection (202A) is joined with the second outer rib projection (202B) via the complementary male energy line and the female energy line (204B) to seal the two-part casing, and
wherein during sealing of the first part (104A) with the second part (104B) of the two-part casing, the plurality of cell layers (106) are compressed in a defined pressure range between the first part (104A) and the second part (104B) such that a direct contact is established between each current collector layer of the set of current collector layers and corresponding electrode layers of the set of electrode layers.
2. The battery device (102) as claimed in claim 1, wherein the set of current collector layers comprises a plurality of cathode current collector layers (304A-304N), and wherein each cathode current collector layer is sandwiched between two corresponding cathode layers disposed on either side of each cathode current collector layer.
3. The battery device (102) as claimed in claim 1, wherein the set of current collector layers comprises a plurality of anode current collector layers (312A-312N), and wherein each anode current collector layer is sandwiched between two anode layers disposed on either side of each anode current collector layer.

4. The battery device (102) as claimed in claim 1, wherein the set of electrode layers comprises a plurality of anode layers (310A-310N) and a plurality of cathode layers (306A-306N), and wherein a thickness of each cathode layer is greater than each anode layer.
5. The battery device (102) as claimed in claim 1, wherein the battery device (102) is a zinc-based monopolar battery in which the plurality of cell layers (106) are compressed devoid of any glue, any sealing blocks, or any frames to hold each current collector layer of the set of current collector layers.
6. The battery device (102) as claimed in claim 1, wherein the defined pressure range in which the plurality of cell layers (106) are compressed between the first part (104A) and the second part (104B) is in a range of 20-80 kg/cm2.
7. The battery device (102) as claimed in claim 1, wherein a stack of the plurality of cell layers (106) is compressed within a range of 20-70% of an original size of the stack of the plurality of cell layers.
8. The battery device (102) as claimed in claim 1, wherein the predefined sequence is a first cathode current collector layer (304A), a first cathode layer (306A), a first separator layer (308A), a first anode layer (310A), a first anode current collector layer (312A), a second anode layer (310B), a second separator layer (308B), a second cathode layer (306B), a second cathode current collector layer (304B), a third cathode layer (306C), a third separator layer (308C), a third anode layer (310C), a second anode current collector layer (312B), and so on.
9. The battery device (102) as claimed in claim 1, wherein the two-part casing is in a half-and-half configuration.
10. A method (600) for assembling a battery device (102), comprising:
arranging a plurality of cell layers (106) comprising a set of electrode layers, a set of separator layers, and a set of current collector layers in a predefined sequence;
placing a stack of the plurality of cell layers (106) arranged in the predefined sequence on a first part of a two-part casing of the battery device (102);
placing a second part (104B) of the two-part casing on top of the stack of the plurality of cell layers (106) and the first part (104A); and
sealing the first part (104A) with the second part (104B) of the two-part casing by compressing the stack of the plurality of cell layers at a defined pressure range within the first part (104A) and the second part (104B) such that a direct contact is established between each current collector layer of the set of current collector layers and corresponding electrode layers of the set of electrode layers,
wherein the sealing of the first part (104A) with the second part (104B) comprises joining a first outer rib projection (202A) of the first part (104A) with a second outer rib projection (202B) of the second part (104B) of the two-part casing, and
wherein the joining of the first outer rib projection (202A) with the second outer rib projection (202B) comprises heat sealing a male energy line (204A) provided on the first outer rib projection (202A) against a female energy line (204B) provided on the second outer rib projection (202B) to seal the two-part casing.