Bipolar Battery Plate Segmentation for Expansion Accommodation
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Solution Overview
Problem
Bipolar batteries face challenges in electrically isolating anode and cathode electrodes in neighboring electrochemical cells, preventing electrolyte leakage, and accommodating electrode expansion in the z-direction, which can lead to strain and potential short circuits.
Innovation Solution
The design separates the bipolar plate into two layers at the perimeter of the electrode stack, with a seal that hermetically isolates each electrochemical cell and accommodates expansion by creating a gap region between the metal layers, allowing for flexible movement and accommodating up to 10% expansion in the z-direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bipolar plate is made as a single rigid layer to ensure electrochemical isolation, then the isolation effectiveness is improved, but the ability to accommodate electrode expansion is worsened
Solution Approach 1:
The bipolar plate is divided into two separate metal layers (first metal layer and second metal layer) with a gap between them at the peripheral ends. This segmentation allows each layer to independently accommodate expansion while maintaining the electrochemical isolation function through the seal disposed in the gap region.
Solution Approach 2:
A seal is introduced as an intermediary element disposed in the gap region between the first and second metal layers. This seal provides electrochemical isolation while allowing the metal layers to move independently to accommodate electrode expansion in the z-direction.
2Reliability
If the seal is made rigid to ensure hermetic sealing, then the sealing effectiveness is improved, but the ability to accommodate expansion is worsened
Solution Approach 1:
The seal is designed as a flexible element that can deform to accommodate expansion of the electrochemical cell in the z-direction while maintaining hermetic sealing. The flexible nature of the seal allows it to stretch and compress with electrode swelling without compromising the electrochemical isolation.
3Ease of manufacture
If the bipolar plate structure is simplified to reduce manufacturing complexity, then the ease of manufacture is improved, but the ability to simultaneously achieve isolation and expansion accommodation is worsened
Solution Approach 1:
The bipolar plate is segmented into two metal layers with a gap, allowing independent optimization of each component's function. This segmentation enables the first metal layer to form one side of the electrochemical cell, the second metal layer to form the other side, and the seal to provide both isolation and expansion accommodation.
Solution Approach 2:
The seal serves multiple functions simultaneously: it provides hermetic sealing to prevent electrolyte leakage, maintains electrochemical isolation between adjacent cells, and accommodates expansion of the electrochemical cell in the z-direction through its flexible nature.
Data Source
AI summary
A bipolar battery including a first electrochemical cell and a second electrochemical cell is provided.