Bipolar Battery Plate Assembly with Polymer Frame
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Solution Overview
Problem
Monopolar lead acid batteries suffer from low energy density, poor cycling performance under high-current-rate or deep discharge conditions, and high self-discharge rates, limiting their effectiveness in various applications compared to other battery chemistries.
Innovation Solution
The development of a bipolar battery plate assembly using a thin lead sheet or silicon substrate with a polymer frame and support ribs, coated with active materials, which suppresses parasitic current paths and reduces weight while maintaining structural integrity and sealing to prevent electrolyte leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If monopolar lead acid battery configuration is used, then manufacturing simplicity and low cost are achieved, but energy density is reduced
Solution Approach 1:
The battery is divided into multiple bipolar plates, each containing multiple electrochemical cells arranged in series. This segmentation allows increased active material utilization and energy density while maintaining manufacturing simplicity through modular assembly of identical plate units.
Solution Approach 2:
The patent transitions from traditional monopolar to bipolar configuration, fundamentally changing the current flow path from end-to-end through a single electrode to alternating current direction through both electrodes of each cell. This dimensional change in electrical architecture enables higher energy density while preserving ease of manufacture.
2Device complexity
If monopolar lead acid battery configuration is used, then structural simplicity is maintained, but cycling performance deteriorates under high-current-rate or deep discharge conditions
Solution Approach 1:
Multiple electrochemical cells are segmented within each bipolar plate, with each cell contributing to the overall series connection. This segmentation distributes the electrical load across multiple cells, improving cycling performance under high-current-rate conditions while maintaining structural simplicity through repetitive plate design.
Solution Approach 2:
The bipolar configuration changes the electrical parameters of the battery system, enabling better current distribution and voltage characteristics. This parameter change improves cycling performance and deep discharge capability while maintaining acceptable structural simplicity.
3Device complexity
If monopolar lead acid battery configuration is used, then design simplicity is achieved, but self-discharge rate increases
Solution Approach 1:
The bipolar plate structure segments the electrochemical cells electrically, with each cell isolated from others except through the series connection via the bipolar plate. This segmentation reduces parasitic current paths between cells, lowering self-discharge rates while maintaining design simplicity through modular plate construction.
4Weight of moving object
If thin lead sheet substrate is used in bipolar configuration, then weight is reduced, but structural integrity may be compromised
Solution Approach 1:
The bipolar plates use composite construction combining thin lead sheet substrate with active material coatings and polymer frame structures. This composite approach reduces overall weight while maintaining structural integrity through the combined properties of different materials working together.
Solution Approach 2:
The patent employs thin lead sheet substrates (thin films) as the base structure for bipolar plates. These thin films are sufficient for the application while significantly reducing weight, with structural integrity maintained through the bipolar configuration and active material deposition.
5Reliability
If polymer frame with support ribs is added to bipolar plate assembly, then sealing and structural support are improved, but device complexity increases
Solution Approach 1:
The polymer frame with support ribs performs multiple functions simultaneously: providing sealing to prevent electrolyte leakage, offering structural support for the thin lead sheet, and maintaining electrical isolation between adjacent cells. This multi-functionality improves reliability while minimizing the increase in device complexity.
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 configuration enhances energy density, improves cycling performance, and reduces self-discharge rates, making bipolar batteries more efficient and durable for diverse applications.
Implementation Method 1
a first cladding of a positive active materials layer covering an area of the first surface of the substrate; and, a second cladding of a negative active materials layer covering an area of the second surface
Data Source
AI summary
A current collector plate assembly including a polygon-shaped electrically conductive substrate having a first surface and a second, opposing, surface, and at least three edges. A frame is coupled to regions of the first and second surfaces near the at least three edges of the substrate. A first cladding of a positive active materials layer covers an area of the first surface of the substrate. A second cladding of a negative active materials layer covers an area of the second surface of the substrate.