Bipolar Battery Stack Assembly With Projecting Separator Edges
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Solution Overview
Problem
The existing manufacturing process for bipolar battery stacks is lengthy due to the need for multiple curing steps per battery cell, which can lead to short circuits between carrier foils of neighboring bipolar electrodes if the sealing material is not fully cured.
Innovation Solution
The solution involves making the separator larger in area than the bipolar electrodes, with the separator projecting laterally beyond the carrier foil edge region of each bipolar electrode. This design prevents warping of the carrier foil edges and ensures that the separator acts as a reliable spacer, preventing short circuits even when pressure is applied during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple curing steps are performed per battery cell to ensure proper sealing, then sealing reliability is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The separator is designed to project laterally beyond the carrier foil edge region before assembly, creating a pre-positioned barrier that prevents carrier foil warping and short circuits in advance. This preliminary structural arrangement eliminates the need for multiple post-assembly curing steps to ensure sealing reliability.
Solution Approach 2:
The laterally projecting separator acts as an intermediary element between adjacent bipolar electrodes, physically preventing carrier foil edges from warping toward each other. This mediator structure ensures sealing reliability by maintaining proper spacing without requiring extensive curing processes.
2Reliability
If the separator projects laterally beyond the carrier foil edge region, then short circuit prevention is improved, but material usage and device complexity increase
Solution Approach 1:
The separator is functionally segmented into two regions: a central region that contacts the electrode assembly and lateral projections that extend beyond the carrier foil edge region. This segmentation allows the separator to perform multiple functions - electrical insulation where needed and mechanical spacing where projected - without requiring complex multi-component designs.
Solution Approach 2:
The laterally projecting separator serves multiple functions simultaneously: it provides electrical insulation between adjacent electrodes, acts as a mechanical spacer to prevent carrier foil warping, and guides the sealing material during assembly. This multi-functionality reduces overall device complexity by consolidating multiple protective functions into a single component.
3Manufacturing precision
If pressure is applied during assembly to ensure contact, then electrical contact quality is improved, but carrier foil warping and short circuits may occur
Solution Approach 1:
The laterally projecting separator is positioned in advance to counteract the potential harmful effect of pressure-induced carrier foil warping. By projecting beyond the carrier foil edges before pressure application, the separator creates a physical barrier that prevents adjacent carrier foils from warping toward each other, thereby eliminating short circuit risks even when assembly pressure is applied to ensure good electrical contact.
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 allows for a faster and more economical assembly of bipolar battery stacks by eliminating the need for multiple curing steps and preventing short circuits, thereby enhancing the efficiency and reliability of the battery stack.
Implementation Method 1
an electrically insulating, ion-permeable, planar separator
Implementation Method 2
an electrically insulating, ion-permeable, planar separator
Implementation Method 3
applying a first sealing bead of an extrudable sealing material to the carrier foil edge region
Data Source
AI summary
A method of manufacturing a bipolar battery stack (10) provides a first bipolar electrode (12) with an electrically conductive carrier foil (121) and a central region (124) coated on both sides with electrode material. A carrier foil edge (125) completely surrounds the central region (124) and is free of electrode material. A first sealing bead (201) is on the carrier foil edge region (125) to surround the carrier foil central region (124). An electrically insulating, ion-permeable, planar separator (18) is placed on the first sealing bead (201) laterally beyond the carrier foil central region (124). A second sealing bead (202) is applied to the edge region of the separator (18) beyond the carrier foil central region (124) to form a ring encircling the carrier foil central region (124), and another one is placed on the second sealing bead (202). The method repeats these steps a predetermined number of times.