Pasted Bipolar Battery Collectors With Clean-Cut Isolation Edges
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Solution Overview
Problem
Current methods for manufacturing bipolar batteries are inefficient in mass production due to challenges in creating clean perimeters around current collectors for electrolytic isolation, which affects battery impedance, cycle life, and overall performance.
Innovation Solution
A method involving the application of paste material to an elongate strip of substrate material, followed by ultrasonic cutting or crush cutting to create individual substrates with current collector bodies placed directly on the wet paste, ensuring proper adhesion and bonding without drying processes, and using equipment like belt pasting machines and rotary punch assemblies for efficient substrate preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods are used to create clean perimeters around current collectors with sealing materials and secondary carriers, then electrolytic isolation is achieved, but manufacturing efficiency and productivity are reduced
Solution Approach 1:
The invention removes secondary carriers (pasting paper, mesh, AGM) and sealing materials (o-rings, adhesives, overmolding) from the manufacturing process. By directly pasting active material onto the current collector perimeter, the process eliminates intermediate components and steps, achieving both clean perimeters for electrolytic isolation and improved manufacturing efficiency
Solution Approach 2:
The invention creates clean perimeters on the current collector before pasting the active material. By preparing the perimeter surface in advance and ensuring it is free of contaminants and active material, the process achieves reliable electrolytic isolation while maintaining continuous manufacturing flow without requiring post-pasting sealing operations
2Ease of operation
If secondary carriers are used to accept paste material and facilitate placement on current collectors, then ease of operation is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The invention eliminates secondary carriers entirely from the process. By directly applying paste material to the current collector, it removes the intermediate carrier components and the associated steps of transferring paste from carrier to current collector, thereby reducing device complexity while maintaining ease of operation through direct pasting
3Ease of operation
If non-stick barriers are used during cutting to prevent paste adhesion, then ease of operation is improved, but adhesion strength between paste and current collector deteriorates
Solution Approach 1:
The invention creates clean perimeters on the current collector before pasting, allowing direct adhesion of paste to the current collector surface without non-stick barriers. By preparing the surface in advance, the process achieves both clean cuts and strong adhesion, eliminating the need for barrier materials that would interfere with bonding
Solution Approach 2:
The invention changes the timing and state of the paste material during processing. By pasting and cutting while the paste is in a wet, pliable state, the process enables clean cutting without non-stick barriers, and subsequent drying or curing maintains strong adhesion between the paste and current collector
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 approach enables efficient and effective preparation of pasted substrates for bipolar batteries, enhancing adhesion, reducing impedance, and improving cycle life and performance by maintaining the moisture content of the paste and avoiding non-stick barriers during the cutting process.
Implementation Method 1
Another step may involve ultrasonic cutting the elongate strip of substrate material at the applied paste material. The ultrasonic cutting may utilize an ultrasonic cutter assembly having a blade.
Data Source
AI summary
In the manufacture of pasted current collectors for bipolar batteries, a method of making pasted substrates includes several steps. The substrates can be a plastic sheet, an embedded plastic mesh, a metal mesh, an absorbent glass mat (AGM), or some other material. One step involves applying paste material to an elongate strip of substrate material. Another step involves cutting the elongate strip of substrate material into multiple individual substrates. Further steps can involve punching via a rotary punch, crush cutting, ultrasonic cutting, concealing lateral sections via folding, and/or using one or more mask overlays.