Bipolar Battery Bubble-Free Electrolyte Layering

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Solution Overview

Problem

Bipolar batteries face a reduction in output density due to the incorporation of bubbles between the separator and electrodes, which creates dead spaces that hinder ion permeation and electron movement.

Innovation Solution

A bipolar battery manufacturing method that involves forming a sub-assembly unit with a porous separator permeable by an electrolyte, where the electrolyte is positioned at specific surfaces to prevent bubble incorporation, and then layering these units to ensure the electrolyte permeates through the separator, creating layers that conduct ions effectively between the electrodes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the electrolyte layer is formed by simple layering of bipolar electrode and separator, then the manufacturing process is simple, but bubbles are incorporated into the electrolyte layer causing dead spaces

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidbubble-free electrolyte layer formation

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The separator is pre-permeated with electrolyte before assembly, and the electrolyte is pre-positioned at the first surface of the separator. This preliminary action ensures that when layers are assembled, the electrolyte already occupies the separator pores and prevents bubble incorporation during the layering process, achieving both simplicity and precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The first surface of the separator acts as an intermediary zone where electrolyte is pre-positioned. This intermediary positioning allows the electrolyte to be introduced in a controlled manner before final assembly, preventing bubble entrapment while maintaining manufacturing simplicity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If bubbles remain in the electrolyte layer, then the layered structure is easier to form, but ion permeation and electron movement are hindered reducing output density

Engineering Contradiction:

Improveoutput densityVSAvoidion permeation continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The method converts the potential harm of bubble incorporation into a benefit by using the separator's first surface as a controlled electrolyte introduction zone. The electrolyte is deliberately positioned at this surface before assembly, ensuring complete pore saturation and eliminating dead spaces, thereby achieving high output density and reliable ion permeation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The porous separator structure is utilized to its full potential by pre-permeating it with electrolyte before assembly. The porous structure allows complete electrolyte saturation when introduced at the first surface, ensuring no dead spaces remain and ion permeation is continuous and reliable.

Inventive Principle:

Principle #31Porous materials

3Manufacturing precision

If the electrolyte is positioned at the first surface of the separator before layering, then bubble incorporation is suppressed, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvebubble suppression in electrolyte layerVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The separator is pre-permeated with electrolyte and the electrolyte is pre-positioned at the first surface before final assembly. This preliminary action consolidates the electrolyte introduction step, making the subsequent layering process simpler and more reliable, thus reducing overall process complexity while achieving high precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The separator's porous structure serves itself by automatically absorbing and holding the electrolyte at its first surface during the pre-permeation step. This self-service mechanism eliminates the need for complex electrolyte distribution systems during assembly, maintaining manufacturing simplicity while achieving precise bubble-free electrolyte layer formation.

Inventive Principle:

Principle #25Self-service

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 method enhances the output density of bipolar batteries by preventing bubble incorporation and ensuring uninterrupted ion movement, thereby reducing battery resistance and improving performance.

Implementation Method 1

a porous separator which is permeable by an electrolyte... making the electrolyte permeate through the separator

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

the electrolyte positioned at the first surface permeate through the separator to one of positive and negative electrodes... containing an electrolyte that conducts ions

Methodology Applied

Scientific EffectIon conduction: Conduction (electrical)

Data Source

PatentUS8734984B2Bipolar battery manufacturing method, and bipolar battery

Publication Date: 2014.05.27 NISSAN MOTOR CO LTD

AI summary

When a bipolar battery is manufactured, a bipolar electrode and a separator are prepared first. Then, one electrode (for example, a positive electrode) out of positive and negative electrodes is applied with such an amount of electrolyte as being exposed on a surface of the one electrode. Then, the separator is arranged on the surface of the one electrode applied with the electrolyte, thus forming a sub-assembly unit. Then, a plurality of the sub-assembly units are layered, and the electrolyte applied to the one electrode is made to permeate through the separator to the other electrode, thus forming an assembly unit.