Bipolar Battery Electrode Bonding to Block Electrolyte Infiltration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional lead-acid storage batteries face issues with low reliability due to corrosion of positive lead layers by sulfuric acid, leading to potential short circuits and performance deterioration, as well as joining failures during manufacturing and liquid junctions caused by adhesive contamination during welding.
Innovation Solution
A bipolar storage battery design incorporating a conductive adhesive between the bipolar plate and electrodes to prevent electrolyte infiltration and ensure reliable bonding, using a conductive adhesive to reduce resistance and prevent sparks during welding, thereby enhancing the battery's durability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional adhesive is used to bond the substrate and lead layer, then bonding reliability is improved, but electrical conductivity is insufficient causing joining failures during welding
Solution Approach 1:
The adhesive's electrical resistance parameter is changed from high (conventional adhesive) to low (conductive adhesive with resistance of 10^-6 to 10^-2 ohm·cm), enabling the adhesive to conduct electricity during welding while maintaining bonding reliability
Solution Approach 2:
The adhesive is formulated as a composite material containing conductive fillers (such as metal particles or carbon materials) dispersed in a polymer matrix, combining the bonding properties of adhesives with the electrical conductivity of conductive materials
2Ease of manufacture
If the positive lead layer is directly bonded to the substrate without adhesive, then manufacturing simplicity is improved, but corrosion resistance is insufficient leading to short circuits
Solution Approach 1:
The conductive adhesive serves as an intermediary layer between the positive lead layer and the substrate, providing both mechanical bonding and corrosion protection while maintaining electrical conductivity to prevent short circuits
Solution Approach 2:
The adhesive is formulated as a composite material containing conductive fillers (such as metal particles or carbon materials) dispersed in a polymer matrix, combining the bonding properties of adhesives with the electrical conductivity of conductive materials
3Strength
If plating method is used to laminate substrate and lead layer, then bonding strength is improved, but manufacturing complexity increases and reliability remains low
Solution Approach 1:
The mechanical/chemical plating process is replaced with a simpler adhesive bonding process that uses conductive adhesives, reducing manufacturing complexity while maintaining bonding strength and improving reliability through better corrosion protection
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
The use of a conductive adhesive between the bipolar plate and electrodes in the bipolar storage battery effectively suppresses corrosion-induced performance degradation, reduces joining failures, and minimizes liquid junction occurrences, ensuring reliable conduction and improved battery performance.
Implementation Method 1
a first adhesive provided between the one surface of the substrate and the positive lead layer to bond the positive lead layer to the substrate
Implementation Method 2
the adhesive layer has a volume resistivity of 1.0×10^-6 to 1.0×10^-2 ohm·cm
Implementation Method 3
effectively suppresses corrosion-induced performance degradation, reduces joining failures, and minimizes liquid junction occurrences
Data Source
AI summary
A bipolar storage battery includes a bipolar electrode including a positive electrode, a negative electrode, and a substrate provided with the positive electrode on one surface and the negative electrode on another surface. The bipolar storage battery includes a first adhesive provided between the one surface of the substrate and the positive electrode to bond the positive electrode to the substrate. The first adhesive is a conductive adhesive. This configuration can provide a bipolar storage battery in which battery performance is less likely to deteriorate by preventing an electrolytic solution from easily infiltrating an interface between a positive electrode and an adhesive layer even when growth occurs in the positive electrode due to corrosion by sulfuric acid contained in the electrolytic solution.