Bipolar Battery Current Collectors for Crack-Free Multi-Layer Lamination
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Solution Overview
Problem
Multi-layer bipolar batteries face issues with current collector breakage during lamination, leading to ionic shortages and reduced voltage, and existing solutions that prevent this require extensive processing time and result in loose connections between layers, causing instability and shorter battery life.
Innovation Solution
The use of current collectors with specific yield strength (50-1000 MPa) and high ductility (5-15% elongation) to prevent cracking during multi-layer lamination, allowing for simultaneous lamination of multiple cells without breaking, using materials like metal foils or composites with carbon fillers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current collectors with high strength are used to prevent breakage during lamination, then reliability improves, but manufacturing precision deteriorates due to elastic deformation and delaminating
Solution Approach 1:
The patent applies parameter changes by precisely controlling the yield strength of the current collector within 50-1000 MPa and elongation at break within 5-15%. This optimization balances the mechanical properties to prevent both breakage during lamination and delamination due to excessive elastic deformation, resolving the contradiction between reliability and manufacturing precision.
Solution Approach 2:
The patent employs composite materials by combining metal foils (such as aluminum, copper, or stainless steel) with carbon fillers (such as carbon black, carbon nanotubes, or graphite). This composite structure enhances the current collector's mechanical properties and electrical conductivity while maintaining appropriate ductility and strength to prevent both breakage and delamination.
2Reliability
If single layers are fabricated individually to avoid current collector breakage, then reliability improves, but productivity deteriorates due to extensive processing time
Solution Approach 1:
The patent merges multiple cell layers into a single laminated structure, allowing simultaneous fabrication of multi-layer batteries. By optimizing the current collector's mechanical properties (yield strength 50-1000 MPa, elongation 5-15%), the process enables lamination of multiple layers without breakage, significantly improving productivity while maintaining reliability.
Solution Approach 2:
The patent changes the mechanical parameters of the current collector to enable multi-layer lamination. By controlling yield strength within 50-1000 MPa and elongation at break within 5-15%, the current collector can withstand the lamination process for multiple layers without breaking, allowing high-throughput production of multi-layer batteries.
3Productivity
If stacked single layers are used to achieve high voltage, then productivity improves, but reliability deteriorates due to loose connections and instability
Solution Approach 1:
The patent merges multiple layers into a tightly laminated structure where the optimized current collector (yield strength 50-1000 MPa, elongation 5-15%) ensures strong mechanical and electrical connections between layers. This eliminates the loose connections problem of stacked single layers while maintaining high productivity through simultaneous multi-layer fabrication.
Solution Approach 2:
The patent uses composite current collectors with metal foils and carbon fillers to enhance both the mechanical bonding strength and electrical conductivity between layers. This composite structure ensures stable, tight connections in laminated multi-layer batteries while maintaining high production throughput.
4Reliability
If current collectors with high ductility are used to prevent cracking, then reliability improves, but strength deteriorates leading to over expansion
Solution Approach 1:
The patent applies parameter changes by optimizing both ductility (elongation at break 5-15%) and strength (yield strength 50-1000 MPa) of the current collector. This balanced parameter selection prevents cracking during lamination while controlling over-expansion, resolving the contradiction between reliability and strength.
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 approach enhances production throughput and electrical performance by preventing cell shorting, increasing yield, and ensuring stable connections between layers, thus extending battery life.
Implementation Method 1
each of the first current collectors has a yield strength greater than or equal to 50 MPa to prevent over expansion and less than or equal to 1000 MPa to prevent delaminating due to elastic deformation
Data Source
AI summary
A method of forming a stacked bipolar battery laminates a plurality of layered cells of the stacked bipolar battery together at a single time.