Bipolar Cell Edge Insulation for Housing-Free Battery Stacks
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Solution Overview
Problem
The existing battery designs with series-connected electrochemical cells face inefficiencies due to the need for gas-impermeable housings and complex insulation, which increase manufacturing costs and reduce efficiency by occupying space and materials.
Innovation Solution
A battery design featuring a stacked arrangement of electrochemical cells with bipolar plates, solid electrolyte layers, and edge insulating devices that allow direct series connections without intervening housings, using a flexible laminate housing to prevent humidity entry and allowing cells to expand/contract without short-circuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cells are enclosed in gas-impermeable housings with insulating structures, then electrical insulation between adjacent cells is ensured, but battery efficiency is reduced and manufacturing complexity increases
Solution Approach 1:
The patent removes the traditional gas-impermeable housing and replaces it with a flexible laminate structure. The edge insulating device is extracted as a separate functional element that can be selectively positioned only where electrical insulation is needed, eliminating unnecessary housing components and reducing manufacturing complexity while maintaining insulation reliability
Solution Approach 2:
The flexible laminate housing serves multiple functions: it provides structural support, allows cell expansion/contraction, and works in conjunction with the edge insulating device for electrical insulation. This multi-functional design replaces the need for separate rigid housings and insulating structures, reducing overall device complexity
2Reliability
If traditional housings and insulating structures are used, then electrical insulation is provided, but space and materials are consumed reducing battery efficiency
Solution Approach 1:
The patent extracts the insulation function from the bulk housing material and concentrates it in thin edge insulating devices positioned only at critical interfaces between cells. This eliminates unnecessary material consumption and frees up space within the battery pack, directly improving battery efficiency by reducing the volume occupied by non-active components
Solution Approach 2:
The patent employs thin flexible laminate structures instead of bulky rigid housings. The edge insulating devices are thin film elements that provide electrical insulation with minimal thickness, significantly reducing the space consumed by insulation materials and improving the active material density of the battery
3Reliability
If rigid housings are used to prevent short circuits, then electrical insulation is maintained, but cells cannot expand or contract freely
Solution Approach 1:
The patent replaces rigid housings with flexible laminate structures that can accommodate cell expansion and contraction during charge/discharge cycles. The flexible nature of the laminate allows dynamic adaptation to cell volume changes while maintaining structural integrity and electrical insulation through the edge insulating devices
Solution Approach 2:
The patent introduces dynamic adaptability by using flexible materials that can change their configuration in response to cell volume changes. The edge insulating devices maintain electrical insulation throughout the dynamic range of cell expansion and contraction, ensuring reliability under varying operational conditions
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 enhances efficiency by eliminating housing-related inefficiencies, allowing cells to expand/contract freely while preventing short circuits, thus improving power generation and reducing manufacturing complexity and costs.
Implementation Method 1
The solid electrolyte layer is disposed on the second surface so as to encapsulate the second active material layer including the second active material layer peripheral edge
Implementation Method 2
the edge insulating device physically contacts and is directly secured to the first surface of one cell of the pair of adjacent cells or the solid electrolyte layer of the other cell of the pair of adjacent cells
Implementation Method 3
the battery housing configured to prevent humidity from entering an interior space of the battery housing
Data Source
AI summary
A battery includes a stacked arrangement of electrochemical cells. Each electrochemical cell is free of a cell housing and includes a bipolar plate having a substrate, a first active material layer formed on a first surface of the substrate, and a second active material layer formed on a second surface of the substrate. Each cell includes a solid electrolyte layer that encapsulates at least one of the active material layers, and an edge insulating device that is disposed between the peripheral edges of the substrates of each pair of adjacent cells. The edge insulating device physically contacts and is directly secured to one of the first surface of one cell and the solid electrolyte layer of an adjacent cell, and is movable relative to, the other of the first surface of the one cell and the solid electrolyte layer of the adjacent cell.