Bipolar Battery Tab Configuration for Short-Circuit Prevention

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Solution Overview

Problem

Bipolar batteries face challenges in achieving high energy density and output due to structural limitations, such as the risk of short-circuits and increased internal resistance when attempting to increase electrode area or connect bipolar units in parallel, which complicates the integration of insulating layers and current collection tabs.

Innovation Solution

A non-aqueous electrolyte battery design that includes an electrode group with stacked positive, negative, and bipolar electrodes separated by insulating members, featuring unique current collecting tab configurations to prevent short-circuits and enhance energy density, allowing for series and parallel connections while maintaining low resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If electrode areas of positive and negative electrodes are increased to achieve higher energy density, then energy density is improved, but counter electrodes come into contact with each other causing short-circuits

Engineering Contradiction:

Improveenergy densityVSAvoidshort-circuit prevention

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The bipolar electrode is divided into multiple segments along the stacking direction, with insulating layers placed between adjacent bipolar electrodes. This segmentation prevents direct contact between counter electrodes while maintaining high energy density through optimized electrode area utilization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An insulating layer is introduced as an intermediary between adjacent bipolar electrodes to prevent short-circuits. This insulating layer allows the electrodes to be closely arranged for high energy density while providing necessary electrical isolation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If bipolar units are connected in parallel to increase output, then power output is improved, but internal resistance increases due to complex tab connections

Engineering Contradiction:

Improvepower outputVSAvoidtab connection complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

Multiple current collecting tabs are integrated into a single unified tab structure that collects current from multiple electrodes simultaneously. This merging simplifies the connection structure for parallel configurations while maintaining low internal resistance through optimized current collection paths.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The current collecting tab structure is designed to serve multiple functions: collecting current from multiple electrodes, providing mechanical support, and enabling both series and parallel connections through a single standardized interface, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If insulating layers are added between bipolar electrode layers to prevent short-circuits, then short-circuit prevention is improved, but thickness of electrode body increases reducing filling rate

Engineering Contradiction:

Improveshort-circuit preventionVSAvoidfilling rate

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

Thin film insulating layers are used between bipolar electrode layers to provide adequate electrical isolation while minimizing thickness increase. This maintains high filling rate in the battery case while ensuring reliable short-circuit prevention.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The design achieves higher energy density and lower internal resistance in bipolar batteries by preventing short-circuits and simplifying the manufacturing process through distinct tab connections, enabling efficient energy storage and release.

Implementation Method 1

a short-circuit (liquid junction) may be caused by ionic conduction between the positive electrode and the negative electrode

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Implementation Method 2

a bipolar battery using a gel electrolyte obtained by making a liquid electrolyte being semisolid is proposed. The gel electrolyte is produced by soaking an electrolytic solution into a polymer

Methodology Applied

Scientific EffectGel structure: Gel

Data Source

PatentUS10559843B2Non-aqueous electrolyte battery, non-aqueous electrolyte battery pack, and vehicle

Publication Date: 2020.02.11 KK TOSHIBA

AI summary

A non-aqueous electrolyte battery includes an electrode group including positive, negative and bipolar electrodes and separators interposed between these electrodes. In the positive electrode, positive electrode active material layers are formed on both side surfaces of a current collector. In the negative electrode, negative electrode active material layers are formed on both side surfaces of a current collector. In the bipolar electrode, positive and negative electrode active material layers are formed on both side surfaces of a current collector respectively. In the group, these electrodes are stacked with the interposed separators. The group includes current collecting tabs for these electrodes. Connecting portions of these tabs are arranged in different positions on an outer periphery of the group.