Bipolar Electrode Lamination Using Carbon Films and Resin Collector

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Solution Overview

Problem

Conventional bipolar electrode manufacturing methods require significant amounts of metal, which is not efficiently utilized, and the conductive resin layer used as a current collector lacks self-supporting properties, making it difficult to form electrode layers on it.

Innovation Solution

A manufacturing method for a bipolar electrode that uses a conductive resin layer as a current collector instead of metal foils, supported by a sheet-form support material, allowing for the formation of self-supporting layers and reducing metal usage. The method involves forming carbon films and electrode layers on the conductive resin layer, with the support material being separated after layer formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If a conductive resin layer is used as a current collector instead of metal foils, then metal usage is reduced, but the layer lacks self-supporting properties making electrode layer formation difficult

Engineering Contradiction:

Improvemetal usageVSAvoidease of forming electrode layer

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

A support material is introduced as an intermediary carrier during the manufacturing process. The support material temporarily supports the conductive resin layer, enabling electrode layer formation. After the electrode layers are formed on both faces, the support material is separated, leaving the conductive resin layer with self-supporting properties achieved through the carbon films.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Carbon films are formed on both faces of the conductive resin layer to create a composite structure. This composite material provides the necessary mechanical strength and self-supporting properties to the conductive resin layer, enabling it to serve as a current collector without metal foils while maintaining ease of manufacture.

Inventive Principle:

Principle #40Composite materials

2Reliability

If carbon film is formed on both faces of the conductive resin layer, then electron conductivity in plane direction is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectron conductivityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The carbon films serve multiple functions: they improve electron conductivity in the plane direction, provide mechanical strength for self-supporting properties, and facilitate the separation of the support material. This multi-functionality justifies the additional manufacturing step by delivering multiple benefits simultaneously.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The carbon films are formed on the conductive resin layer before the electrode layers are formed. This preliminary action ensures that the carbon films are already in place to provide conductivity and mechanical support during subsequent handling and assembly processes, simplifying the overall manufacturing flow.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the support material is separated after electrode layer formation, then self-supporting layer is achieved, but separation difficulty arises with non-fluororesin materials

Engineering Contradiction:

Improvehandling propertiesVSAvoidseparation difficulty

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The support material uses fluororesin, which has specific physical and chemical parameters including low surface energy and non-stickiness. These parameter changes in the material properties enable easy separation from the carbon film and electrode layers after the electrode layers are formed, while still providing adequate support during the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

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 method significantly reduces metal usage while enabling the formation of bipolar electrodes with improved electron conductivity in both thickness and plane directions, enhancing handling properties and sealing properties in bipolar batteries.

Implementation Method 1

The conductive resin layer can exhibit sufficient electron conductivity in a thickness direction

Methodology Applied

Scientific EffectElectron conductivity: Conduction (electrical)

Implementation Method 2

forming carbon film on both faces of the conductive resin layer can be expected to improve in the electron conductivity in the plane direction

Methodology Applied

Scientific EffectElectron conductivity enhancement: Conduction (electrical)

Implementation Method 3

Fluororesin tends to have excellent releasability (non-stickiness). By the support material containing a fluororesin, separation of the support material is expected to be facilitated

Methodology Applied

Scientific EffectNon-stickiness: Hydrophobe

Data Source

PatentUS20250183249A1Manufacturing method of bipolar electrode, and bipolar electrode

Publication Date: 2025.06.05 TOYOTA JIDOSHA KK

AI summary

A manufacturing method of a bipolar electrode includes the following (a) to (f). (a) A first carbon film is formed on the sheet-shaped support material. (b) A conductive resin layer is formed on the first carbon film. (c) A second carbon film is formed on the conductive resin layer. (d) A second electrode layer is formed on the second carbon film. (e) The support is separated from the first carbon coating. (f) A bipolar electrode is manufactured by forming a first electrode layer on the first carbon film.