Bipolar Battery Current Collector With Through-Hole Adhesive Bonding
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Solution Overview
Problem
Existing bipolar batteries face challenges in improving energy density due to the thickness increase caused by outer conductive adhesive layers used for bonding electrode active material layers.
Innovation Solution
A current collector design where first and second current collectors are bonded via a conductive adhesive layer that penetrates through holes in the collectors, eliminating the need for outer adhesive layers, thereby reducing thickness and enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If outer conductive adhesive layers are used for bonding electrode active material layers to current collectors, then adhesion is ensured, but battery thickness increases and energy density decreases
Solution Approach 1:
The current collector is designed with through-holes that allow the conductive adhesive layer to penetrate through the entire thickness. This porous structure enables the adhesive to form strong bonds at both the front and back surfaces of the current collector, ensuring reliable adhesion between the electrode active material layers and the current collector without requiring additional outer adhesive layers.
Solution Approach 2:
The adhesive bonding mechanism is transitioned from a two-dimensional surface application (outer adhesive layers) to a three-dimensional penetration through the current collector thickness. The conductive adhesive layer passes through the through-holes in the vertical dimension, creating bonds at multiple depths and surfaces, which eliminates the need for additional outer adhesive layers and reduces overall battery thickness.
2Reliability
If conventional bonding methods are used, then adhesion is achieved, but interface resistance increases and energy density is reduced
Solution Approach 1:
The through-holes in the current collector create a porous pathway that allows the conductive adhesive layer to penetrate and establish direct electrical contact with both electrode active material layers. This reduces the number of adhesive interfaces and minimizes contact resistance, while the conductive nature of the adhesive layer ensures efficient electron transport across the current collector.
Solution Approach 2:
The current collector structure combines the mechanical strength of the current collector material with the conductive and adhesive properties of the conductive adhesive layer. This composite structure ensures both strong adhesion and low interface resistance, as the conductive adhesive layer serves dual functions of bonding and electrical conduction throughout the current collector thickness.
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 reduces interface resistance and allows for improved energy density by direct contact between the current collector and electrode active material layers, while maintaining effective adhesion without additional thickness.
Implementation Method 1
a first current collector and a second current collector are bonded via a conductive adhesive layer
Implementation Method 2
a first current collector and a second current collector are bonded via a conductive adhesive layer
Data Source
AI summary
In the current collector for a bipolar battery of the present disclosure, the first current collector and the second current collector are bonded to each other via a conductive adhesive layer, the first current collector is provided with a first through hole, the conductive adhesive layer is inserted into the first through hole, and/or the second current collector is provided with a second through hole, and the conductive adhesive layer is inserted into the second through hole. In the bipolar battery of the present disclosure, the first electrode active material layer is bonded to the current collector for the bipolar battery by the conductive adhesive layer that has entered the first through hole, and/or the second electrode active material layer is bonded to the current collector for the bipolar battery by the conductive adhesive layer that has entered the second through hole.