Bipolar Battery Plate With Conductive Polymer Substrate
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Solution Overview
Problem
Conventional bipolar batteries require complex external support structures and multiple processing steps, leading to increased costs and complexity in production, particularly due to the use of metallic substrates that cause corrosion and gassing issues.
Innovation Solution
A bipolar battery design featuring a frame with a non-conductive insulative plastic substrate having conductive particles or fibers, where lead layers are positioned on either side of the substrate, and active materials are applied directly to the lead layers, eliminating the need for a separate external support structure and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic substrates (lead and alloys) are used in bipolar batteries, then substrate strength is improved, but corrosion and gassing increase
Solution Approach 1:
The patent employs a composite substrate consisting of a non-conductive polymer matrix (such as polyethylene, polypropylene, or polyester) reinforced with conductive fibers (graphite, carbon, or metal fibers). This composite structure provides the necessary mechanical strength while the polymer matrix prevents corrosion and gassing issues associated with pure metallic substrates. The conductive fibers embedded in the polymer create conductive pathways without the harmful corrosion effects of metallic substrates.
Solution Approach 2:
The substrate design incorporates localized conductive regions within an otherwise non-conductive polymer matrix. Conductive fibers or particles are strategically distributed to provide electrical conductivity only where needed for current collection, while the bulk polymer material maintains corrosion resistance and chemical stability. This local quality approach allows the substrate to simultaneously achieve strength, conductivity, and corrosion resistance.
2Strength
If conventional bipolar battery construction with separate frame and substrate is used, then structural support is provided, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the previously separate frame and substrate into a single integrated component. The substrate itself is designed with sufficient mechanical strength and rigidity to serve both as the electrical conductor support and as the structural frame. This integration eliminates the need for separate frame structures, reducing the number of parts, simplifying assembly procedures, and lowering manufacturing costs while maintaining adequate structural support for the battery cells.
Solution Approach 2:
The substrate is designed to perform multiple functions simultaneously: it provides structural support (replacing the frame), serves as the mounting surface for active materials, conducts electricity through embedded fibers, and prevents electrolyte leakage. This multi-functionality reduces device complexity by consolidating multiple components into a single universal element.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces production costs and complexity by integrating the substrate and frame into a single, moldable unit, minimizing parts and assembly steps while providing a robust and corrosion-resistant bipolar battery structure.
Implementation Method 1
The substrate includes insulative plastic with conductive particles or fibers, where lead layers are positioned on either side of the substrate, and active materials are applied directly to the lead layers, eliminating the need for a separate external support structure. The conductive particles electrically connect the lead layers through the nonconductive substrate.
Data Source
AI summary
A bipolar battery plate is utilized for production of a bipolar battery. The bipolar battery plate includes a frame, a substrate, first and second lead layers, and positive and negative active materials. The substrate includes insulative plastic with conductive particles homogeneously dispersed throughout the insulative plastic and exposed along surface of the substrate, the substrate positioned within the frame. The first lead layer is positioned on one side of the substrate, while the second lead layer is positioned on another side of the substrate. The first and second lead layer are electrically connected to each through the conductive particles. The positive active material is positioned on a surface of the first lead layer, and the negative active material positioned on a surface of the second lead layer.