User:Dorkmo/Ideas/Battery: Difference between revisions

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idea is to use loose powder contained in tubs with mesh walls.
[[Image:Battery-design-overview.png|400px|right]]


[[Nickel-Iron_Battery]]
idea is to use powder contained in tubs. the walls will have a perforated mesh whos holes angle up and out so that the powder cannot escape. Nickel wires will be placed in the powder to conduct out of the cell. -'''Contact area is not optimal - that's why they use liquid electrolyte?-MJ'''


[https://drive.google.com/folderview?id=0BwxMMqGvwTM-dElBSUpQYWtMdnM&usp=sharing google doc folder]
*[[Nickel-Iron_Battery]]
*[[Nickel-Iron_Battery/Chemistry]]
**[http://en.wikipedia.org/wiki/Nickel%E2%80%93iron_battery#Electrochemistry Wikipedia]
**[http://electronicspani.com/nickel-iron-battery/ electronicspani.com - NiFe Battery]


[[Image:Image20141109-batteryprogress.jpg|400px]]
[[User:Dorkmo/Log]]
 
[http://drive.google.com/folderview?id=0BwxMMqGvwTM-dElBSUpQYWtMdnM&usp=sharing Google Docs Folder]


=design=
=design=
==principles==
*maximize 3d printing
**utilize parametric customization
*avoid complicated chemical processing
**no nickel plating


==ideas==
==ideas==
*powders are very likely to become airborne
**internet has suggested that "black strap molases" was added to edison batteries
**might try to mix in at different ratios to see what happens to consitency


*add a couple super capacitors to get some cold cranking amps?
*add a couple super capacitors to get some cold cranking amps?
Line 34: Line 50:
*need to make parametric for 10 tub battery
*need to make parametric for 10 tub battery
**maybe input number of rows and columns so it can be a single row or two side by side
**maybe input number of rows and columns so it can be a single row or two side by side
*might move side spacers onto cages. 3 sphere divots. 1 middle top and 2 side by side bottom, flip on opposite face. 1 or 2 on non mesh sides.
==lessons learned==
*3d printing with layers most often leads to leaks
**can sometimes hold but not reliably.
***perhaps in the future print settings could be optimized
**need to use a regular plastic container for tub
***perhaps half gallon milk jug


==sketches==
==sketches==
Line 41: Line 67:
[[File:BATTERY-idea-20141012.skp]]
[[File:BATTERY-idea-20141012.skp]]


<html><iframe src="https://3dwarehouse.sketchup.com/embed.html?mid=ub3514fdf-5f46-459b-a0ed-433a83daab1f&width=400&height=300" frameborder="0" scrolling="no" marginheight="0" marginwidth="0" width="400" height="300" allowfullscreen></iframe></html>


==scad work==
==scad work==
[[Image:Ose-battery-images-20141118-scad.png|400px]]
parametric code to produce stl files for custom sized 3d prints.


[[User:Dorkmo/Ideas/Battery/SCAD]]
[[User:Dorkmo/Ideas/Battery/SCAD]]
Line 48: Line 80:
==chemistry==
==chemistry==


http://en.wikipedia.org/wiki/Nickel%28II%29_hydroxide
:[http://en.wikipedia.org/wiki/Nickel%28II%29_hydroxide Nickel Hydroxide]
:[[Nickel-Iron_Battery/Chemistry]]
:[http://en.wikipedia.org/wiki/Nickel%E2%80%93iron_battery#Electrochemistry Wikipedia]
:[http://electronicspani.com/nickel-iron-battery/ electronicspani.com - NiFe Battery]
 
===KOH corrosion===
 
*need to find out if ABS or PLA or other plastics will hold up to corrosion by the electrolyte
 
[http://www.roymech.co.uk/Useful_Tables/Corrosion/Corr_plastic.html chart]
 
[http://www.lati.com/en/technical_data/chemical_resistance_01.html chart]


==calculations==
==calculations==


*nickel carbonate
**4.39 g/cm3
*nickel hydroxide Ni(OH)2
*nickel hydroxide Ni(OH)2
**4.10 g/cm3
**4.10 g/cm3
===to research later===
:would liked to have an info for:
::Ah/gram
::impact surface area has
::calculate AWG output based on dimensions of cage and cells
=analysis=
Need to find a battery analyzer.
*[http://www.paulallenengineering.com/store/p2/2_Slot_AA_Charger%2C_Standard_SD_Data_Logging%2C_External_Drain%2C_With_Case.html UltraSmartCharger]


=bom=
=bom=
Line 73: Line 127:
*nuts
*nuts
**
**
==chemicals==
*[http://www.sigmaaldrich.com/catalog/product/aldrich/283622?lang=en&region=US Ni(OH)2] [http://www.gfschemicals.com/statics/productdetails/NICKEL_HYDROXIDE_5191.html]
*[http://www.artistsupplysource.com/product/53758/potassium-hydroxide-caustic-potash-1-kg-2-2-lb-bag-made-in-usa-by-natural-pigments/?utm_source=AR-froogle_Product-Ads&utm_medium=Natural_Pigments&utm_campaign=NAP-500-21POH1K&gclid=CLLop8-ZrrYCFaFxQgodKhoAuQ&xid0=07b2299bc82b20977180722ece0cbc3f KOH] [http://www.amazon.com/Potassium-Hydroxide-Caustic-Potash-Flakes/dp/B00KCYOFCI/ref=sr_1_1?ie=UTF8&qid=1416543631&sr=8-1&keywords=potash+lye]
*[http://www.amazon.com/Black-Iron-Oxide-Natural-Pounds/dp/B008LE63H6/ Fe3O4] [http://alphachemicals.com/]
*[http://www.amazon.com/Dixon-Graphite-Microfyne-463-LMF1-Category/dp/B004F7JD5M/ C] [http://www.asburystore.com/SearchResults.asp?Cat=1814]
[http://www.chemexper.com/search/cas/12054487.html supplier directory]
==wire==
*[http://www.temcoindustrialpower.com/search.html?category=Special_Metal_Wire Nickel Wire]
==Misc==
*[http://www.walmart.com/ip/Slow-As-Blackstrap-Molasses-32-oz-Pack-of-6/17770607 Molasses]
=Notes=
*internet sometimes suggests having 2:1 nickel hydroxide to iron ratio
*initial charge
**a few places have suggested that a short (30min) small charge happen 1 day before a full charge
**couldnt find any info on why this would be
==mixes==
*it is suggested to add graphite to nickel hydroxide
**internet says 17% graphite
**will try 85% nickel hydroxide 15% graphite to keep it simple
*one source said graphite is mixed into the iron
**havent seen that suggested anywhere else
*its also suggested that layers of nickel flake were used
**multiple layers were pressed with hydraulic force
*internet suggests 20-30% KOH in electrolyte
**tolerant of different amounts
===version 1===
:1 cup dry Ni hydroxide powder
:1/4 cup dry graphite powder
:then
:1/4 cup black strap molases
:3/16 cup water
=FDM watertightness=
http://www.stratasys.com/solutions/finishing-processes/sealing-fdm-parts
epoxy resin to seal surfaces
*instead use common LDPE containers?

Latest revision as of 03:50, 21 November 2015

Battery-design-overview.png

idea is to use powder contained in tubs. the walls will have a perforated mesh whos holes angle up and out so that the powder cannot escape. Nickel wires will be placed in the powder to conduct out of the cell. -Contact area is not optimal - that's why they use liquid electrolyte?-MJ

User:Dorkmo/Log

Google Docs Folder

design

principles

  • maximize 3d printing
    • utilize parametric customization
  • avoid complicated chemical processing
    • no nickel plating

ideas

  • powders are very likely to become airborne
    • internet has suggested that "black strap molases" was added to edison batteries
    • might try to mix in at different ratios to see what happens to consitency
  • add a couple super capacitors to get some cold cranking amps?
    • not sure if that would work but just an idea
  • two tubs with grid on four sides of each or shared center.
  • fins for surface area.
  • cages that snap in to the bottom of a tub shared by two cages.
  • might use a part of a sphere for the snap in idea.
  • tub lid
    • tub lid will need some sort of two pole terminal block
      • from cages below
      • to next tub or out for use
    • might need some sort of cover for uninsulated wires from cage
    • vent for gas?

Battery-boltterminal.png


  • need to make parametric for 10 tub battery
    • maybe input number of rows and columns so it can be a single row or two side by side
  • might move side spacers onto cages. 3 sphere divots. 1 middle top and 2 side by side bottom, flip on opposite face. 1 or 2 on non mesh sides.

lessons learned

  • 3d printing with layers most often leads to leaks
    • can sometimes hold but not reliably.
      • perhaps in the future print settings could be optimized
    • need to use a regular plastic container for tub
      • perhaps half gallon milk jug

sketches

single cell separated by a grid.

File:BATTERY-idea-20141012.skp

scad work

Ose-battery-images-20141118-scad.png


parametric code to produce stl files for custom sized 3d prints.

User:Dorkmo/Ideas/Battery/SCAD

chemistry

Nickel Hydroxide
Nickel-Iron_Battery/Chemistry
Wikipedia
electronicspani.com - NiFe Battery

KOH corrosion

  • need to find out if ABS or PLA or other plastics will hold up to corrosion by the electrolyte

chart

chart

calculations

  • nickel hydroxide Ni(OH)2
    • 4.10 g/cm3

to research later

would liked to have an info for:
Ah/gram
impact surface area has
calculate AWG output based on dimensions of cage and cells

analysis

Need to find a battery analyzer.

bom

hardware

nickel, aluminum, brass?

chemicals

supplier directory

wire

Misc

Notes

  • internet sometimes suggests having 2:1 nickel hydroxide to iron ratio
  • initial charge
    • a few places have suggested that a short (30min) small charge happen 1 day before a full charge
    • couldnt find any info on why this would be

mixes

  • it is suggested to add graphite to nickel hydroxide
    • internet says 17% graphite
    • will try 85% nickel hydroxide 15% graphite to keep it simple
  • one source said graphite is mixed into the iron
    • havent seen that suggested anywhere else
  • its also suggested that layers of nickel flake were used
    • multiple layers were pressed with hydraulic force
  • internet suggests 20-30% KOH in electrolyte
    • tolerant of different amounts

version 1

1 cup dry Ni hydroxide powder
1/4 cup dry graphite powder
then
1/4 cup black strap molases
3/16 cup water

FDM watertightness

http://www.stratasys.com/solutions/finishing-processes/sealing-fdm-parts

epoxy resin to seal surfaces

  • instead use common LDPE containers?
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