Composite Packaging for Lithium Bipolar Battery Pressure Control
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Solution Overview
Problem
Conventional lithium-ion bipolar batteries face challenges in sealing compartments to prevent electrolyte leaks, leading to malfunction, and existing packaging solutions, whether flexible or rigid, either fail to apply necessary pressure for optimal contact or result in excessive weight reducing specific energy.
Innovation Solution
A composite packaging material comprising a hardened polymer and porous reinforcement, which maintains pressure and contact between bipolar element components, potentially reinforced with conductive or non-conductive materials, and can include a double envelope for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If flexible packaging is used, then weight is reduced, but pressure application capability is insufficient
Solution Approach 1:
The packaging uses a composite structure combining an expandable foam core with an outer shell. The foam material provides both the necessary mechanical pressure application capability and remains lightweight, resolving the contradiction between weight reduction and force application. The composite structure allows the packaging to maintain optimal contact pressure on the bipolar element while keeping overall weight low.
2Force
If rigid packaging is used, then pressure application capability is improved, but weight increases excessively
Solution Approach 1:
The packaging employs a composite design with an expandable foam interior and a thinner outer shell, replacing traditional rigid materials. This composite structure provides sufficient mechanical support and pressure application capability while significantly reducing the overall weight, thus resolving the contradiction between force capability and weight.
Solution Approach 2:
The packaging utilizes the phase change property of expandable foam materials that transition from a compact state to an expanded state. This parameter change allows the packaging to generate and maintain optimal contact pressure on the bipolar element while keeping the material weight low, addressing the contradiction between pressure capability and weight.
3Reliability
If sealing structures are added to prevent electrolyte leaks, then reliability is improved, but device complexity increases
Solution Approach 1:
The expandable foam packaging serves multiple functions simultaneously: it provides structural support, applies optimal contact pressure, and creates sealing against electrolyte leaks. By integrating these multiple functions into a single component, the design improves reliability without significantly increasing device complexity.
Solution Approach 2:
The composite packaging structure with expandable foam and outer shell works together to provide both sealing capability and structural function. This integrated composite design achieves reliable electrolyte containment while maintaining relatively simple overall structure, resolving the contradiction between sealing performance and structural complexity.
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 solution effectively maintains optimal contact and pressure between bipolar element components, preventing electrolyte leaks while minimizing weight, thus enhancing the performance and energy density of lithium-ion bipolar batteries.
Implementation Method 1
maintaining a determined pressure on either side of the bipolar element so as to maintain a determined contact between its constituents
Implementation Method 2
encapsulating the bipolar element... preventing electrolyte leaks
Data Source
Figure 1~2C
Figure 3A~3E
Figure 4A~4B
AI summary
The invention relates to novel casing for a lithium bipolar electrochemical battery (A) including a bipolar element. According to the invention, the casing is formed by a composite material including a matrix and at least one porous reinforcement, the matrix of which includes at least one hardened polymer with which the porous reinforcement(s) are impregnated. The porous reinforcement(s) (4) and the hardened polymer(s) (5) encase the bipolar element (1) and maintain a predetermined pressure on either side of the latter, so as to maintain a predetermined contact between the components thereof.