Bipolar Battery Plate With Integrated Frame And Perforated Substrate
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Solution Overview
Problem
Conventional bipolar batteries have complex designs requiring multiple layers and external frames for support, which complicates production and limits conductivity between active materials.
Innovation Solution
A bipolar battery design featuring a substrate with perforations and standoffs within a moldable, insulative frame that simplifies the structure by eliminating the need for a complex external frame, enhancing conductivity through lead layers and active material placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bipolar batteries use multiple layers and external frames for support, then structural integrity is maintained, but device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent combines the frame and substrate into a single integrated bipolar plate structure. The substrate is formed as an integral part of the bipolar plate, eliminating the need for separate external frames and multiple layers while maintaining structural support. This merging reduces device complexity and manufacturing difficulty while preserving the necessary structural integrity.
2Strength
If conventional bipolar batteries use multiple layers and external frames, then structural support is provided, but ease of manufacture decreases
Solution Approach 1:
The frame and substrate are merged into a single integrated component that is formed in one manufacturing process. The bipolar plate is created as a unified structure with the substrate already positioned and supported, eliminating the need for separate assembly steps for frames and multiple layers, thereby significantly improving ease of manufacture.
Solution Approach 2:
The substrate is pre-formed and integrated into the bipolar plate structure before the active materials are applied. This preliminary formation of the supported substrate structure simplifies subsequent manufacturing steps and improves overall production efficiency while maintaining structural support.
3Stability of the object's composition
If conventional designs use complex external frames, then structural stability is maintained, but productivity decreases due to complicated production
Solution Approach 1:
The integration of the frame and substrate into a single bipolar plate component reduces the number of parts that need to be manufactured and assembled. This merging simplifies the production process, reduces assembly time, and improves productivity while the integrated structure maintains the necessary structural stability for battery operation.
4Strength
If conventional bipolar batteries use traditional substrate arrangements, then structural support is provided, but conductivity between active materials is limited
Solution Approach 1:
The substrate is positioned in close proximity to the active materials on both sides of the bipolar plate, creating optimal local conditions for conductivity. The integrated design ensures that the substrate is strategically located where it can most effectively conduct ions between the positive and negative active materials, improving reliability without compromising structural support.
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 complexity, enhances conductivity, and allows for customization while maintaining structural integrity and support for the bipolar battery plates.
Implementation Method 1
a first lead layer positioned on one side of the substrate, a second lead layer positioned on another side of the substrate, wherein the first and second lead layers are electrically connected to each other through the plurality of perforations
Data Source
AI summary
A bipolar battery plate for a bipolar battery is disclosed. The bipolar battery plate has a frame, a substrate positioned within the frame, a first lead layer positioned on one side of the substrate, a second lead layer positioned on another side of the substrate, a positive active material (PAM) positioned on a surface of the first lead layer, and a negative active material (NAM) positioned on a surface of the second lead layer. The substrate has a plurality of perforations, and a plurality of standoffs integrally formed on opposing side surfaces thereof. The first and second lead layers are electrically connected to each other through the plurality of perforations.