IP Library Granted Patent US 12665212
Granted Patent B1
US 12665212 · App. 19/419,014 · Granted Jun 23, 2026

Gravitational cascade flow battery

Inventor: Henry Hardy Perritt, Jr. (Charlottesville, VA)
H01M8/188H01M8/0438H01M50/70H01M2300/0025H01M2300/0082H01M2300/0085H01M2300/0091
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Quick Facts
Patent No.
US 12665212
App. No.
19/419,014
Granted
Jun 23, 2026
Kind
B1
Abstract

A gravitational cascade flow battery achieves practical energy density of 200 Wh/L through micro-encapsulated phase change materials and eliminates mechanical components using acoustically-controlled thixotropic flow. The system comprises a vertical tower where gel-state electrolyte slurries flow through cascaded reaction stages only when acoustic chokes locally liquefy the fluid through ultrasonic stimulation. Smooth micro-encapsulated spheres contain crystallizing active materials, preventing membrane and electrode abrasion while maintaining high energy density. Thixotropic behavior created by fumed silica prevents settling at rest but enables rapid flow under acoustic activation. A passive fail-safe system releases hot solvent upon power loss, gravity-flushing the cascade to prevent catastrophic solidification. The acoustic control provides precise digital flow modulation with <100 ms response time while achieving 80-82% round-trip efficiency. Applications include grid-scale energy storage, renewable energy integration, and underground installations utilizing natural or artificial vertical structures.

Claims (66)

1 . A gravitational flow battery system comprising:

a cascade reaction column having a height of at least 10 meters, said cascade reaction column having an upper end and a lower end;

an upper reservoir positioned at the upper end of said cascade reaction column; and

a lower reservoir positioned at the lower end of said cascade reaction column;

said cascade reaction column comprising:

a plurality of electrochemical reaction stages arranged vertically within said cascade reaction column;

a thixotropic electrolyte slurry exhibiting gel behavior at rest and liquid behavior under acoustic stimulation contained within said cascade reaction column;

acoustic chokes positioned between the stages, each acoustic choke comprising a constriction where focused acoustic fields control flow through rheological state changes;

wherein flow of the thixotropic electrolyte slurry is controlled exclusively through acoustically-induced viscosity modulation without mechanical pumps or valves; and

wherein the thixotropic electrolyte slurry comprises a positive electrolyte containing a cerium redox couple in which Ce 3+ is oxidized to Ce 4+ during charging, and a negative electrolyte containing a vanadium redox couple in which V 3+ is reduced to V 2+ during charging, said positive and negative electrolytes being separated by a membrane permitting ion transport while preventing electrolyte mixing, whereby the complementary oxidation and reduction half-reactions generate a cell voltage of approximately 1.35 volts per reaction stage;

wherein said thixotropic electrolyte slurry comprises:

electroactive species in a solution;

fumed silica rheology modifiers;

said thixotropic electrolyte slurry transitioning from gel state exhibiting apparent viscosity greater than 1000 Pa·s to liquid state exhibiting apparent viscosity less than 2 Pa·s under acoustic activation.

2 . The system of claim 1 , further comprising micro-encapsulated phase change particles wherein:

electroactive species are contained within permeable polymer spheres of 50-500 μm diameter;

said spheres comprise cross-linked polyacrylamide shells with 5-20 nm pore size;

crystallization of the electroactive species occurs within said spheres during charging while maintaining smooth external morphology with surface roughness Ra less than 1 μm.

3 . The system of claim 1 , wherein said acoustic chokes comprise:

cylindrical constrictions of 2-5 mm diameter;

radially positioned ultrasonic transducers generating focused fields at 40 kHz;

localized liquefaction zones extending 1-2 cm where shear rate exceeds 1000 s −1 ;

flow rate of the flow of the thixotropic electrolyte slurry proportional to acoustic power following Q=K(P_acoustic){circumflex over ( )}1.7,

where Q is the flow rate in mL/s, K=0.15 mL/(s·W{circumflex over ( )}1.7), and P_acoustic is acoustic power generated by the ultrasonic transducer with the unit of W.

4 . The system of claim 1 wherein the cascade reaction column generates hydrostatic pressure of 1-3 bar through said height of at least 10 meters sufficient to drive flow of the thixotropic electrolyte slurry through the activated acoustic chokes without mechanical pumping.

5 . The system of claim 1 ; further comprising a control system with:

machine learning algorithms predicting optimal acoustic patterns;

rheological state monitoring using ultrasonic sensors; and

sequential stage activation creating controlled flow waves.

6 . The system of claim 2 , wherein said micro-encapsulated phase change particles achieve energy storage density of at least 200 Wh/L through internal phase transitions and wherein said particles exhibit surface roughness Ra less than 1 μm.

7 . The system of claim 2 wherein each of the electrochemical reaction stages comprises:

reticulated vitreous carbon foam electrodes with 45 pores per inch and 92% porosity;

an amphoteric gradient membrane excluding the micro-encapsulated phase change particles while permitting ion transport; and

a hierarchical pore structure of the reticulated vitreous carbon foam electrodes with macropores larger than a maximum size of the micro-encapsulated phase change particles;

wherein the particles are the microencapsulated phase change particle recited in claim 2 .

8 . The system of claim 7 wherein said amphoteric gradient membrane comprises:

a cation-selective sulfonated polyetheretherketone (SPEEK) layer;

an anion-selective quaternized polysulfone layer;

maximum pore diameter of 2 μm preventing crossover of the micro-encapsulated phase change particles;

pH-responsive behavior creating unidirectional ion transport;

wherein the particles are the microencapsulated phase change particle recited in claim 2 .

9 . A gravitational flow battery system comprising:

a cascade reaction column having a height of at least 10 meters, said cascade reaction column having an upper end and a lower end;

an upper reservoir positioned at the upper end of said cascade reaction column and a lower reservoir positioned at the lower end of said cascade reaction column;

a plurality of electrochemical reaction stages arranged vertically within said cascade reaction column;

a thixotropic electrolyte slurry exhibiting gel behavior at rest and liquid behavior under acoustic stimulation contained within said cascade reaction column;

acoustic chokes positioned between the stages, each acoustic choke comprising a constriction where focused acoustic fields control flow through rheological state changes;

wherein flow of the thixotropic electrolyte slurry is controlled exclusively through acoustically-induced viscosity modulation without mechanical pumps or valves;

further comprising a passive fail-safe system including:

a solvent reservoir positioned above said cascade reaction column containing pure acid at 40-60° C.; and

a fail-open magnetic valve held closed by continuous electromagnetic force;

wherein upon power loss, gravity-driven solvent flush dissolves solidified material within 2-5 minutes.

10 . A gravitational flow battery system comprising:

a cascade reaction column having a height of at least 10 meters, said cascade reaction column having an upper end and a lower end;

an upper reservoir positioned at the upper end of said cascade reaction column and a lower reservoir positioned at the lower end of said cascade reaction column;

a plurality of electrochemical reaction stages arranged vertically within said cascade reaction column;

a thixotropic electrolyte slurry exhibiting gel behavior at rest and liquid behavior under acoustic stimulation contained within said cascade reaction column;

acoustic chokes positioned between the stages, each acoustic choke comprising a constriction where focused acoustic fields control flow through rheological state changes;

wherein flow of the thixotropic electrolyte slurry is controlled exclusively through acoustically-induced viscosity modulation without mechanical pumps or valves;

wherein said acoustic chokes comprise:

cylindrical constrictions of 2-5 mm diameter;

radially positioned ultrasonic transducers generating focused fields at 40 kHz;

localized liquefaction zones extending 1-2 cm where shear rate exceeds 1000 s −1 ;

flow rate of the flow of the thixotropic electrolyte slurry proportional to acoustic power following Q=K(P_acoustic) {circumflex over ( )}1.7;

where Q is the flow rate in mL/s, K=0.15 mL/(s·W{circumflex over ( )}1.7), and P_acoustic is acoustic power generated by the ultrasonic transducer with the unit of W; and

wherein said acoustic chokes provide response time <100 ms from closed to open state and automatic closure within 1-2 seconds upon acoustic cessation through thixotropic recovery.