Bipolar Battery Assembly With Transverse Channels And Edge Seals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Bipolar batteries face challenges in commercialization due to internal pressures, heat generation, and complexity in design, which can lead to runaway reactions and damage to the battery materials, along with limited packaging flexibility and high weight.
Innovation Solution
The design incorporates multiple stacks of bipolar plates with dual polar battery plates and monopolar plates, using a liquid electrolyte and conductive substrates to form electrochemical cells, with a membrane seal and conductive conduits to manage pressure and heat, allowing for scalable and lightweight battery assemblies with enhanced power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If bipolar batteries are scaled up to increase capacity, then energy density improves, but internal pressure increases causing seal rupture and battery failure
Solution Approach 1:
The bipolar battery is divided into multiple electrochemical cells arranged in a stack, with each cell separated by bipolar plates. This segmentation allows pressure to be distributed across multiple smaller cells rather than accumulating in a single large cell, enabling scaling of total capacity while managing internal pressure through the modular structure.
2Reliability
If conventional sealing structures are used to contain pressure, then cell sealing improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The bipolar plate serves multiple functions simultaneously: it acts as an electrode (cathode on one side, anode on the other), a separator between cells, and a structural component that provides sealing surfaces. This multi-functionality eliminates the need for separate sealing structures, reducing device complexity while maintaining reliable cell sealing through the integrated design.
3Reliability
If heavy sealing structures and cases are added to manage pressure, then battery reliability improves, but weight increases
Solution Approach 1:
The bipolar plate incorporates localized sealing features (sealing surfaces and channels) only where needed at the edges and interfaces, rather than using heavy overall sealing structures. The sealing function is concentrated at specific locations where pressure management is critical, reducing unnecessary weight while maintaining reliability.
4Reliability
If complex sealing structures are implemented, then pressure containment improves, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The sealing function is merged with the bipolar plate structure itself, which is a single integrated component manufactured as one piece. The bipolar plate includes built-in sealing surfaces and fluid channels that are formed during its manufacturing process, eliminating the need for separate sealing components and simplifying assembly to a straightforward stacking process.
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 solution effectively manages internal pressures and heat, reduces weight, and increases power density while simplifying the assembly process, enabling bipolar batteries to be adapted to various packaging spaces and user needs without complex sealing structures.
Implementation Method 1
an electrolyte, which is a material that allows electrons and ions to flow between the anodic and cathodic material
Implementation Method 2
form an electrochemical cell wherein electrons and ions are exchanged between the anodic material and the cathodic material
Data Source
AI summary
The invention relates to an article comprising: a) one or more stacks of battery plates comprising one or more bipolar plates; b) located between each plate is a separator and a liquid electrolyte; further comprising one of more of the features: 1) c) the one or more stacks of battery plates having a plurality of channels passing transversely though the portion of the plates having the cathode and/or the anode deposited thereon; and d) i) one or more seals about the periphery of the channels which prevent the leakage of the liquid elelctrolyte into the channels, and/or posts located in one or more of the channels having on each end an overlapping portion that covers the channel and sealing surface on the outside of the monopolar plates adjacent to the holes for the transverse channels and applies pressure on the sealing surface of the monopolar plates wherein the pressure is sufficient to withstand pressures created during assembly and operation of electrochemical cells created by the stacks of battery plates; 2) c) a membrane comprising a thermoplastic polymer is disposed about the entire periphery of the edges of the stack of plates; 3 wherein the separator is in the form of a sheet having adhered to its periphery a frame; and m4) c) an integrated valve and integrated channel communicating with the valve.