Reinforced Bipolar Battery End Plates for Vacuum Filling Seals
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Solution Overview
Problem
Bipolar battery assemblies face challenges in maintaining a seal and resisting deformation during vacuum filling and operation, leading to non-uniform filling and potential leakage, particularly due to inward deformation of electrode plates under negative pressure, which is not adequately addressed by existing sealing configurations and end plate designs.
Innovation Solution
The use of reinforced end plates with internal structures, such as rib patterns, attached to both peripheries and inner surfaces of the end plates, providing stiffness of at least 400 ksi to resist both inward and outward deformations, allowing for uniform electrolyte distribution and maintenance of a seal using a single port for vacuum and filling, while minimizing weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy end plates are used to resist deformation during operation, then the structural strength is improved, but the weight of the battery assembly increases
Solution Approach 1:
The end plate uses a composite structure combining a base layer with an integrated foam core. The foam material (polymer, polyurethane, or polyethylene) provides internal reinforcement and structural support, allowing the end plate to maintain high strength while reducing overall weight compared to solid metal plates of equivalent strength.
Solution Approach 2:
The end plate is divided into functional zones: a base layer for structural integrity and a foam core for internal reinforcement. This segmentation allows each layer to contribute its specific properties - the base provides attachment surfaces and structural framework, while the foam provides distributed support and weight reduction.
2Device complexity
If a single port is used for both vacuum creation and electrolyte filling, then the device complexity is reduced, but the reliability of sealing and uniform filling deteriorates
Solution Approach 1:
The single port serves multiple functions: creating vacuum during assembly, filling electrolyte into the battery, and maintaining sealing during operation. The reinforced end plate structure ensures that this multi-functional port maintains reliable sealing under varying pressure conditions (vacuum, positive pressure during filling, and operational pressure differentials).
3Ease of manufacture
If end plates are attached only at the periphery to electrode plates, then the ease of manufacture is improved, but the strength of connection and resistance to deformation deteriorates
Solution Approach 1:
The attachment transitions from two-dimensional peripheral attachment to three-dimensional attachment by extending bonding to the inner surface of the end plate. This adds a new dimension of attachment area, increasing connection strength and deformation resistance while maintaining manufacturing feasibility through surface bonding processes.
Data Source
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Figure 3
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AI summary
An article having (a) one or more stacks of a plurality of electrode plates include: (i) one or more bipolar plates having a substrate having an anode on one surface and a cathode on an opposing surface; (ii) a separator and a liquid electrolyte located between each of the electrode plates; (b) a first end plate having a first end plate internal reinforcement structure, attached at an end of the one or more stacks; (c) a second end plate having a second end plate internal reinforcement structure, attached at an opposing end of the one or more stacks as the first end plate; wherein the first end plate and the second end plate reinforce the plurality of electrode plates during a charge cycle, a discharge cycle, or both the charge cycle and the discharge cycle.