Composite Bipolar Current Collector With Built-In Insulation

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Solution Overview

Problem

Bipolar batteries face issues with short circuits due to contact between current collectors and electrolytes, leading to reduced voltage and premature degradation, necessitating additional insulating parts that increase complexity and reduce energy density.

Innovation Solution

A composite current collector made of conductive and non-conductive materials, where compression forms conductive regions and uncompressed areas remain insulative, eliminating the need for separate insulating parts and preventing short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional insulating parts are added to prevent short circuits between current collectors, then reliability is improved, but device complexity increases and energy density decreases

Engineering Contradiction:

Improveprevention of short circuitsVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the insulating part and current collector into a single integrated component. The insulating layer is formed directly on the current collector substrate, creating a unified structure that provides both electrical conduction and insulation functions simultaneously, thereby reducing the total number of parts while maintaining reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated component performs multiple functions: the current collector substrate conducts electrons, while the insulating layer prevents short circuits. This multi-functional design eliminates the need for separate insulating parts, reducing device complexity without compromising short circuit prevention

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If additional insulating parts are added to prevent short circuits between current collectors, then reliability is improved, but energy density decreases

Engineering Contradiction:

Improveprevention of short circuitsVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

By merging the insulating layer with the current collector into a single integrated component, the patent reduces the total volume occupied by separate parts. This integration minimizes volumetric loss and maximizes the active material volume, thereby improving energy density while maintaining short circuit prevention

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating layer is implemented as a thin film structure on the current collector substrate. This thin film approach provides adequate insulation to prevent short circuits while occupying minimal volume, thus preserving energy density compared to bulkier separate insulating parts

Inventive Principle:

Principle #30Flexible shells and thin films

3Device complexity

If current collectors from different layers come into contact, then device complexity is reduced, but voltage output decreases due to short circuits

Engineering Contradiction:

Improvenumber of joint partsVSAvoidvoltage output

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent merges the insulating function with the current collector structure, allowing current collectors from different layers to be positioned closer together without risk of short circuits. This integration maintains low device complexity while ensuring reliable voltage output through the built-in insulation

Inventive Principle:

Principle #5Merging (Combining)

4Power

If joint parts are used to connect batteries in series, then voltage output is improved, but device complexity increases and energy density decreases

Engineering Contradiction:

Improvevoltage outputVSAvoidnumber of joint parts

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The bipolar battery design merges the current collection and electrical connection functions into a single integrated component. The current collector serves as both the electrical conductor and the structural element for connecting battery layers, eliminating the need for separate joint parts while maintaining high voltage output

Inventive Principle:

Principle #5Merging (Combining)

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 energy density by reducing parts, prevents short circuits, and maintains homogeneous current and temperature distribution, thus improving battery performance and longevity.

Implementation Method 1

compress an area of the mixture so the conductive material of the mixture comes into contact to form a conductive region

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS20250323280A1Current collector for bipolar stacked batteries

Publication Date: 2025.10.16 LASAGNA ONE INC

AI summary

A method for forming a bipolar battery may form a mixture of conductive material and non-conductive material. The method may compress an area of the mixture so the conductive material of the mixture comes into contact to form a conductive region and the mixture that is uncompressed form an insulative region of a current collector of the bipolar battery.