3D Folded Battery Unit for Ion Transport and Short-Circuit Isolation

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Solution Overview

Problem

Current battery technologies face challenges in efficiently manufacturing three-dimensional folded battery units with interdigitated anode and cathode stacks that can be easily integrated into various battery housing geometries, while maintaining electrical integrity and ion transport efficiency.

Innovation Solution

A method involving the folding of anode and cathode assemblies with interdigitated anode and cathode collectors, separated by a separator material, to form a three-dimensional battery unit with a battery housing that accommodates different geometries, using techniques such as die-cutting, spray-coating, and vapor deposition to create thin-film electrodes and interconnects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional battery manufacturing methods are used, then manufacturing process is simple, but manufacturing precision and structural integrity are insufficient for three-dimensional folded configurations

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming the anode and cathode assemblies with interdigitated collectors and separator material in a flat configuration before folding. The separator is pre-positioned between the electrodes, and the assemblies are pre-aligned to ensure proper structural integrity during the subsequent folding process, avoiding the need for complex real-time adjustments during manufacturing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent transitions from two-dimensional flat battery structures to three-dimensional folded configurations by folding the anode and cathode assemblies along defined axes. This dimensional change enables compact packaging while maintaining electrical integrity through the interdigitated collector design that accommodates the folded geometry.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If battery units are designed for compact size, then energy storage density improves, but ion transport efficiency may be compromised

Engineering Contradiction:

Improveenergy storage densityVSAvoidion transport efficiency

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent implements nesting by placing the separator material between the anode and cathode collectors in an interdigitated arrangement, where each collector type is nested within the structure formed by the alternating collectors. This nested configuration maximizes space utilization for energy storage while maintaining adequate separator thickness for ion transport through the folded structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent applies local quality by ensuring that the separator material has sufficient thickness and porosity specifically at the regions where ion transport is critical, while allowing the electrode collectors to be thin for maximum energy density. The interdigitated design creates local variations in structure that optimize both compactness and ion transport pathways.

Inventive Principle:

Principle #3Local quality

3Productivity

If interdigitated anode and cathode stacks are used, then manufacturing efficiency improves, but risk of short circuits increases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidshort circuit risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent uses the separator material as an intermediary element positioned between the anode and cathode collectors in the interdigitated structure. This separator acts as a physical barrier that prevents direct contact between opposing electrodes during the folding and assembly process, eliminating short circuit risks while maintaining the manufacturing efficiency benefits of the interdigitated design.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies beforehand cushioning by pre-positioning the separator material between the electrode collectors before folding occurs. This preliminary protective measure ensures that even if folding variations or tolerances occur during manufacturing, the separator maintains adequate spacing between electrodes to prevent short circuits, cushioning against potential failure modes.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Adaptability or versatility

If battery housing must accommodate various geometries, then adaptability improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvehousing geometry adaptabilityVSAvoidfolding and assembly precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent achieves universality by designing the anode and cathode assemblies with standardized interdigitated collector patterns that can be folded into multiple configurations. The same basic assembly structure can accommodate different housing geometries (cylindrical, prismatic, pouch) by varying the folding pattern, eliminating the need for geometry-specific manufacturing processes and reducing precision requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables the fabrication of compact, efficient battery units with improved ion transport and reduced risk of short circuits, capable of being integrated into diverse battery housing shapes and sizes, enhancing energy storage density and flexibility.

Implementation Method 1

a set of separators arranged between the anode and cathode collectors to prevent direct contact between the anode and cathode collectors and to isolate the anode and cathode collectors from one another

Methodology Applied

Scientific EffectPhysical separation:

Implementation Method 2

using techniques such as die-cutting, spray-coating, and vapor deposition to create thin-film electrodes and interconnects

Methodology Applied

Scientific EffectVapor deposition: Physical Vapour Deposition

Implementation Method 3

enables the fabrication of compact, efficient battery units with improved ion transport

Methodology Applied

Scientific EffectIon transport:

Data Source

PatentUS11923563B2Three-dimensional folded battery unit and methods for manufacturing the same

Publication Date: 2024.03.05 MILLIBATT INC

AI summary

One variation of a battery unit includes: a series of anode collectors; a set of anode electrodes including anode material arranged on both side of the anode collectors; a set of anode interconnects interposed between and electrically coupling adjacent anode collectors and folded to locate the anode collectors in a boustrophedonic anode stack; a series of cathode collectors; a set of cathode electrodes including cathode material arranged on both side of the cathode collectors; a set of cathode interconnects interposed between and electrically coupling adjacent cathode collectors and folded to locate the cathode collectors in a boustrophedonic cathode stack with cathode collectors interdigitated between anode collectors in the boustrophedonic anode stack; and a set of separators arranged between the anode and cathode electrodes and transporting solvated ions between the anode and cathode electrodes.