Flow Battery Structures to Improve Performance and Reduce Manufacturing Cost

Redox flow batteries are a promising technology for electrical energy storage for renewable energy sources; however traditional redox flow batteries are limited in their use due to non-uniform pressure drops and mass transfer limitations, as well as high manufacturing costs related to the felt material costs for the electrode and component alignment challenges during manufacturing. The overall objective of the proposed program is to validate alpha/beta scale manufacturing of redox flow battery components with greater power/energy densities while substantially reducing stack components and associated manufacturing costs compared to current state-of-the-art flow battery technology. By replacing the traditional felt electrode material with electrodes that are coupled with thin metallic bipolar plates that utilize specially engineered structures such as arrays of posts, pyramids and/or pillars, acceptable pressure drops can be realized while still increasing reactant mass transfer rates. This will eliminate costs associated with the felt and component alignment thus decreasing the impact of the stack cost for the manufacturing of redox flow batteries. Commercial Applications and Other Benefits: Improving the economics of redox flow batteries through reduced manufacturing costs could make them an attractive electrical energy storage system for traditional utilities, grid service providers and equipment suppliers. In addition, redox flow batteries can supplement renewable energy sources by storing power for delivery at peak demand. One potential specific market for economical redox flow batteries is in commercial buildings due to their large percentage of energy consumption.