Bipolar Electrode Structure With Elastic Layer to Suppress Warping

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Solution Overview

Problem

Bipolar batteries face the challenge of warping during charging and discharging due to the different expansion and contraction behaviors of the composite layers in the electrodes.

Innovation Solution

The bipolar electrode design includes a cathode substrate, a cathode composite layer, an anode substrate, an anode composite layer divided by grooves, and an elastic layer between the anode substrate and the anode composite layer, which are stacked in a specific sequence to absorb expansion and contraction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If composite layers with different expansion and contraction behaviors are used in bipolar electrodes, then electrode capacity and performance are improved, but warping develops during charging and discharging

Engineering Contradiction:

Improveelectrode performanceVSAvoidwarping

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The anode composite layer is divided into multiple regions by grooves, creating segmented structures that can independently expand and contract. This segmentation prevents uniform stress accumulation across the entire layer, thereby reducing warping while maintaining the performance benefits of composite materials with different expansion characteristics.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An elastic layer is introduced between the anode substrate and the anode composite layer to provide flexibility and accommodate expansion/contraction differences. This elastic layer acts as a buffer that absorbs dimensional changes, preventing warping while allowing the composite layers to maintain their performance-enhancing composition.

Inventive Principle:

Principle #30Flexible shells and thin films

2Stability of the object's composition

If elastic layer is added to suppress warping, then electrode stability is improved, but device complexity increases

Engineering Contradiction:

Improveelectrode stabilityVSAvoidstructure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The elastic layer serves multiple functions simultaneously: it suppresses warping by accommodating expansion differences, maintains electrical contact between layers, and provides mechanical support to the anode composite layer. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The elastic layer is formulated as a composite material combining polymer matrix with conductive fillers, integrating mechanical elasticity and electrical conductivity in a single layer. This approach avoids the need for separate elastic and conductive components, thus minimizing structural complexity while achieving both warping suppression and electrical functionality.

Inventive Principle:

Principle #40Composite materials

3Shape

If grooves are formed in anode composite layer, then expansion is absorbed and warping is suppressed, but manufacturing precision requirements increase

Engineering Contradiction:

Improvewarping suppressionVSAvoidgroove formation precision

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The groove dimensions (width, depth, spacing) are optimized within specific parameter ranges to achieve effective warping suppression while accommodating manufacturing tolerances. By selecting appropriate parameter values, the design balances warping control performance with manufacturability, reducing the stringency of precision requirements.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The groove structure is designed to self-accommodate expansion forces through its geometric configuration, reducing the need for ultra-precise manufacturing. The grooves naturally expand and contract with the composite layer, providing a self-regulating mechanism that tolerates reasonable manufacturing variations while maintaining warping suppression effectiveness.

Inventive Principle:

Principle #25Self-service

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 effectively suppresses warping during charging and discharging by allowing the elastic layer to absorb the expansion of the anode composite layer, ensuring the stability of the bipolar battery.

Implementation Method 1

an elastic layer having elastic properties that is formed between the anode substrate and the anode composite layer

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20250192372A1Bipolar electrode and bipolar battery

Publication Date: 2025.06.12 TOYOTA JIDOSHA KK

AI summary

A bipolar electrode includes a cathode substrate that configures a current collector, a cathode composite layer formed on the cathode substrate, an anode substrate that configures a current collector, an anode composite layer that is formed on the anode substrate and that is divided into plural regions by a groove between adjacent regions of the plurality of regions, with the anode substrate as a bottom portion of the groove, and an elastic layer having elastic properties that is formed between the anode substrate and the anode composite layer. The electrode includes the cathode composite layer, the cathode substrate, the anode substrate, the elastic layer, and the anode composite layer stacked in this sequence.