AN OUTLET MANIFOLD WITH SPECIFIC FLOW PATTERN

Applicant hereby claims priority to U.S. Patent Application No. 13/194,486 filed July 29, 2011, the disclosure of which is herein incorporated by reference.

BACKGROUND

1. Technical Field

[0001] This disclosure relates generally to a flow battery and, more particularly, to a flow battery having one or more flow battery cells arranged between an inlet manifold and an outlet manifold.

2. Background Information

[0002] A typical flow battery system includes a flow battery stack, an anolyte reservoir and a catholyte reservoir. An anolyte solution is circulated between the anolyte reservoir and the flow battery stack. A catholyte solution is circulated between the catholyte reservoir and the flow battery stack.

[0003] The flow battery stack may include a relatively large number of (e.g., greater that one hundred) flow battery cells. The flow battery cells may be serially connected to increase power and voltage of the flow battery system. The anolyte and catholyte solutions typically flow in relatively long and parallel paths through the cells. Electrical shunt currents may be induced within the solutions where, for example, adjacent flow battery cells have different electrical potentials. Such shunt currents may reduce efficiency of the flow battery system.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 illustrates an exploded view flow battery stack;

[0005] FIG. 2 illustrates a first plate surface of a first manifold plate;

[0006] FIG. 3 illustrates a second plate surface of the first manifold plate illustrated in

FIG. 2;

[0007] FIG. 4 illustrates a first plate surface of a second manifold plate;

[0008] FIG 5 illustrates a second plate surface of the second manifold plate illustrated in FIG. 4; and [0009] FIG. 6 illustrates a plurality of flow battery cells that are separated by a bipolar plate.

DETAILED DESCRIPTION

[0010] FIG. 1 illustrates a flow battery stack system 10. The flow battery stack system

10 extends longitudinally between an inlet end 12 and an outlet end 14. The flow battery stack system 10 extends laterally between a first side 16 and a second side 18. The flow battery stack system 10 extends vertically between a third side 20 (e.g., a top side) and a fourth side 22 (e.g., a bottom side). The flow battery stack system 10 includes an inlet cover plate 24, an outlet cover plate 26, an inlet manifold 28, an outlet manifold 30, an inlet frame plate 32, and outlet frame plate 34, a first current collector 36, a second current collector 38, and a flow battery cell stack 40.

[0011] The inlet cover plate 24 includes a first solution inlet 42 and a second solution inlet 44. The first and second solution inlets 42 and 44 extend longitudinally through the inlet cover plate 24.

[0012] The outlet cover plate 26 includes a first solution outlet 46 and a second solution outlet 48. The first and second solution outlets 46 and 48 extend longitudinally through the outlet cover plate 26.

[0013] The inlet manifold 28 includes an inlet first manifold plate 50 and an inlet second manifold plate 52. The outlet manifold 30 includes an outlet first manifold plate 54 and an outlet second manifold plate 56.

[0014] FIG. 2 illustrates a first plate surface of the first manifold plates 50 and 54. FIG.

3 illustrates a second plate surface of the first manifold plates 50 and 54 illustrated in FIG. 2. Referring to FIGS. 2 and 3, each of the inlet and outlet first manifold plates 50, 54 includes one or more inlet / outlet first passages 58, 60, one or more first distribution passages 62, 64, a first solution well 66, 68, one or more first solution flow apertures 70, 72, and a second solution flow aperture 74, 76, respectively. The first passages 58, 60 are disposed on a first plate surface 78 (see FIG. 2), and serpentine and extend from the first solution well 66, 68 to the first solution flow apertures 70, 72. The apertures 74, 76 extend longitudinally through the manifold plate 50, 54, respectively. The first distribution passages 62, 64 are disposed on a second plate surface 80 (see FIG. 3), and extend from the first solution flow apertures 70, 72 to respective second ends 82, 84 thereof.

[0015] FIG. 4 illustrates a first plate surface of the second manifold plates 52 and 56.

FIG. 5 illustrates a second plate surface of the second manifold plates 52 and 56 illustrated in FIG. 4. Referring to FIGS. 4 and 5, each of the inlet and outlet second manifold plates 52, 56 includes one or more inlet / outlet second passages 86, 88, one or more second distribution passages 90, 92, a second solution well 94, 96, one or more first solution flow apertures 98, 100, and one or more second solution flow apertures 102, 104, respectively. The second passages 86, 88 are disposed on a first plate surface 106 (see FIG. 4), and serpentine and extend from the second solution well 94, 96 to the second solution flow apertures 102, 104. The second solution flow apertures 102, 104 extend longitudinally through the second manifold plate 52, 56. The second distribution passages 90, 92 are disposed on a second plate surface 108 (see FIG. 5), and extend from the second solution flow apertures 102, 104 to respective second ends 110, 112 thereof. The first solution flow apertures 98, 100 extend longitudinally through the second manifold plate 52, 56.

[0016] Referring to FIGS. 2 and 4, the first passages 58, 60 and/or the second passages

86, 88 may be arranged in a parallel and tortuous (e.g., serpentine) configuration. For ease of description, the configuration of the first and second passages will be described below with reference to the first passages 58 illustrated in FIG. 2.

[0017] Referring to FIG. 2, the tortuous configuration of the first passages 58 is designed to reduce shunt current losses within the flow battery stack system 10. Each of the first passages 58 may include, for example, a plurality of passage segments 114-122 that may be serially connected to provide the respective first passage 58 with a relatively long length for increasing (e.g., maximizing) its resistance to shunt currents.

[0018] The passage segments 114-122 may have straight, arced, bent, curved, spiraled and/or twisted geometries. In the embodiment illustrated in FIG. 2, for example, the passage segments include a plurality of counter- flow passage segments 114, a plurality of substantially straight passage segments 116, 118 and 120, and a plurality of curved passage segments 122. Each counter-flow passage segment 114 includes a first passage segment 124 and a second passage segment 126. The first passage segment 124 is connected to the second passage segment 126 such that a solution flows through the first passage segment 124 in a first direction, and through the second passage segment 126 in a second direction that is substantially opposite to the first direction. The straight passage segments include a plurality of laterally extending passage segments 116 and 120, and a vertically extending passage segment 118.

[0019] The passage segments 114- 122 may also be configured to form a plurality of flow regions 128 and 130 within the first passage 58. In the embodiment illustrated in FIG. 2, for example, each of the counter-flow and laterally extending passage segments 114, 116 and 120 is configured having a first passage width. The vertically extending passage segment 118 is configured having a second passage width that is less than the first passage width. The vertically extending passage segment 118 induces a greater flow rate and pressure drop (per unit length) than the counter- flow and laterally extending passage segments 114, 116 and 120 since the second passage width is less than the first passage width. Thus, the counter-flow and laterally extending passage segments 114, 116 and 120 form a first flow region 128, and the vertically extending passage segment 118 forms a second flow region 130.

[0020] The passage segments 114-122 may also be configured to direct a solution flowing through the first passage 58 to the vertically extending passage segment 118. In such a configuration, gas entrained in the solution may stagnate proximate a connection between the vertically extending passage segment 118 and the laterally extending passage segment 116, where the entrained gas rises through the solution faster than the solution flows down the vertically extending passage segment 118. Gas stagnation may be reduced or prevented, however, by selecting the second passage width such that the flow rate and pressure drop induced in the second flow region 130 are large enough to force the entrained gas down through the vertically extending passage segment 118 against buoyancy. In this manner, the relatively high flow rate and pressure induced within the second flow region 130 may increase efficiency of the flow battery stack system 10.

[0021] Referring again to FIG. 1, the inlet frame plate 32 includes one or more first inlet apertures 132, one or more second inlet apertures 134, and a central aperture 136. The first and the second inlet apertures 132 and 134 maybe disposed adjacent the fourth side 22, and extend longitudinally through the inlet frame plate 32. The central aperture 136 extends longitudinally through the inlet frame plate 32.

[0022] The outlet frame plate 34 includes one or more first outlet apertures 138, one or more second outlet apertures 140, and a central aperture 142. The first and the second outlet apertures 138 and 140 may be disposed adjacent the third side 20, and extend longitudinally through the outlet frame plate 34. The central aperture 142 extends longitudinally through the outlet frame plate 34.

[0023] The flow battery cell stack 40 includes one or more flow battery cell sub-stacks

144. Each flow battery cell sub-stack 144 includes a sub-stack frame 146 and a plurality of flow battery cells 148.

[0024] The sub-stack frame 146 includes one or more first inlet apertures 150, one or more second inlet apertures 152, one or more first outlet apertures 154 and one or more second outlet apertures 156. An example of such a sub-stack frame is disclosed in U.S. Patent No.

7,682,728.

[0025] FIG. 6 illustrates a plurality of flow battery cells 148 that are separated by a bipolar plate 158. Each flow battery cell 148 includes a separator 160 disposed between a first electrode layer 162 and a second electrode layer 164. The separator 160 maybe an ion-exchange membrane. The first and the second electrode layers 162 and 164 may be liquid-porous electrode layers. Examples of a bipolar plate, separator and electrode layers are disclosed in PCT/US09/68681, and U.S. Patent Application Serial Nos. 13/084,156 and 13/023,101, each of which is incorporated by reference in its entirety.

[0026] Referring to FIGS. 1 and 6, the first electrode layers 162 are arranged in fluid communication with a first flow path that extends through channels 157 in the bipolar plate 158 between the first inlet apertures 150 and the first outlet apertures 154. The second electrode layers 164 are arranged in fluid communication with a second flow path that extends through channels 159 in the bipolar plate 158 between the second inlet apertures 152 and the second outlet apertures 156.

[0027] Referring to FIG. 1, in an assembled flow battery stack configuration (not shown), the flow battery cell sub-stacks 144 are mated together to form the flow battery cell stack 40. The first current collector 36 is positioned in the central aperture 136, and is electrically connected to the flow battery cell stack 40. The second current collector 38 is positioned in the central aperture 142, and is electrically connected to the flow battery cell stack 40.

[0028] The inlet frame plate 32 is mated with the flow battery cell stack 40 such that the first inlet apertures 132 are connected to the first inlet apertures 150, and the second inlet apertures 134 are connected to the second inlet apertures 152. The outlet frame plate 34 is mated with the flow battery cell stack 40 such that the first outlet apertures 138 are connected to the first outlet apertures 154, and the second outlet apertures 140 are connected to the second outlet apertures 156.

[0029] Referring to FIGS. 1-5, the inlet first manifold plate 50 is mated with the inlet second manifold plate 52 such that the second ends 82 of the first distribution passages 62 are connected to the first solution flow apertures 98, and the second solution flow aperture 74 is connected to the second solution well 94. The outlet first manifold plate 54 is mated with the outlet second manifold plate 56 such that the second ends 84 of the first distribution passages 64 are connected to the first solution flow apertures 100, and the second solution flow aperture 76 is connected to the second solution well 96.

[0030] The inlet manifold 28 is mated with the inlet frame plate 32 such that the first solution flow apertures 98 are connected to the first inlet apertures 132, and the second ends 110 of the second distribution passages 90 are connected to the second inlet apertures 134. The outlet manifold 30 is mated with the outlet frame plate 34 such that the first solution flow apertures 100 are connected to the first outlet apertures 138, and the second ends 112 of the second distribution passages 92 are connected to the second outlet apertures 140. In this manner, the flow battery cells 148 are connected axially between the inlet and outlet manifolds 28 and 30.

[0031] The inlet cover plate 24 is mated ith the inlet manifold 28 such that the first solution inlet 42 is connected to the first solution well 66, and the second solution inlet 44 is connected to the second solution flow aperture 74. The outlet cover plate 26 is mated with the outlet manifold 30 such that the first solution outlet 46 is connected to the first solution well 68, and the second solution outlet 48 is connected to the second solution flow aperture 76.

[0032] Referring to FIG. 1 , during operation, a first solution (e.g., a vanadium anolyte) having a first reversible reduction-oxidation ("redox") couple reactant (e.g., V ²⁺ and/or V ³⁺ ions) is directed through the first solution inlet 42 and into the tortuous inlet first passages 58 of the inlet manifold 28. The inlet manifold 28 directs the first solution into the flow battery cells 148 through the inlet frame plate 32. The first solution passes through the channels 157 in the bipolar plate 158 adjacent to the first electrode layers 162, and wets the first electrode layers 162 (see FIG. 6). The first solution, for example, can be forced through the first electrode layers 162 via an interdigitated-type flow field, or simply contact a surface of the electrode layers 162. The first solution is subsequently directed into the tortuous first passages 60 of the outlet manifold 30 through the outlet frame plate 34. The outlet manifold 30 directs the first solution out of the flow battery stack system 10 through the first solution outlet 46.

[0033] A second solution (e.g., a vanadium catholyte) having a second reversible redox couple reactant (e.g., V ⁴⁺ and/or V ⁵⁺ ions) is directed through the second solution inlet 44 and into the tortuous inlet second passages 86 of the inlet manifold 28. The inlet manifold 28 directs the second solution into the flow battery cells 148 through the inlet frame plate 32. The second solution passes through the channels 159 in the bipolar plate 158 adjacent to the second electrode layers 164, and wets the second electrode layers 164 (see FIG. 6). The second solution, for example, can be forced through the second electrode layers 164 via an interdigitated-type flow field, or simply contact a surface of the electrode layers 164. The second solution is

subsequently directed into the tortuous second passages 88 of the outlet manifold 30 through the outlet frame plate 34. The outlet manifold 30 directs the second solution out of the flow battery stack system 10 through the second solution outlet 48.

[0034] During an energy storage mode of operation, an electrical current received by the current collectors 36 and 38 (see FIG. 1) is converted to chemical energy. The conversion process occurs through electrochemical reactions in the first solution and the second solution, and a transfer of non-redox couple reactants (e.g., H ⁺ ions) from the first solution to the second solution across each of the flow battery cells 148 and, in particular, each of the separators 160 (see FIG. 6). The chemical energy is then stored in the first solution and the second solution, which may be respectively stored in first and second reservoirs (not shown). During an energy discharge mode of operation, the chemical energy stored in the first and second solutions is converted to electrical current through reverse electrochemical reactions in the first solution and the second solution, and the transfer of the non-redox couple reactants from the second solution to the first solution across each of the flow battery cells 148. The electrical current is then output from the flow battery stack system 10 through the current collectors 36 and 38.

[0035] In an alternate embodiment, the first and second passages may be disposed on opposite sides of a manifold plate.

[0036] In another alternate embodiment, the first and second passages in one of the inlet and outlet manifolds may have a substantially non-tortuous configuration.

[0037] In some embodiments, the manifold plates 50, 52, 54, and 56, the sub-stack frames 146, and/or the frame plates 32, 34 are constructed from a non-el ectrically conducting material (i.e., an insulator) such as, for example, plastic or a plastic-composite material (e.g., fiber reinforced plastic). The material may be selected to be relatively easy to mold into the complex shapes of the aforesaid components. The material may also be selected to have a glass- transition temperature that is higher than a predetermined threshold such as a maximum operating temperature of the flow battery stack system 10; e.g., a glass transition temperature greater than approximately sixty degrees Celsius for a vanadium-redox battery. Examples of suitable materials include thermoplastics, thermosets or semi-crystalline plastics (e.g., HDPE, PEEK).

[0038] In some embodiments, at least a portion of the bipolar plate 158 (e.g., a portion of the plate contacting active areas of the adjacent flow battery cells) is constructed from a corrosion resistant, electrically-conductive material. Examples of suitable materials include carbon (e.g., graphite, etc.), or metals with corrosion resistant coatings.

[0039] In some embodiments, the first and second current collectors 36 and 38 may be constructed from a material having a relatively high electrical conductivity, and a relatively low contact resistance with an adjacent component (e.g., a bipolar plate) within the cell stack 40. The first and second current collectors 36 and 38 may be configured as, for example, gold-plated copper plates.

[0040] While various embodiments of the present flow battery stack have been disclosed, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible. Accordingly, the present flow battery stack is not to be restricted except in light of the attached claims and their equivalents.