S-Shaped Folded Bipolar Solid-State Batteries Without Tabs or Welds
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Solution Overview
Problem
Bipolar batteries face challenges such as contamination from electrode punching, internal short-circuits due to blocker failure, non-uniform pressure on electrodes, and inefficient space utilization in conventional stacking or winding methods.
Innovation Solution
The design of bipolar batteries with S-shaped folded electrodes that eliminate welded tabs and busbars, allowing for efficient space utilization and scalability, reducing contamination and short-circuit risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stacking-type bipolar batteries are used, then electrode assembly is simplified, but contamination risk increases due to electrode punching
Solution Approach 1:
The bipolar electrode is divided into multiple segments that are folded back and forth within the battery container. This segmentation eliminates the need for punching holes through the entire electrode stack, thereby reducing contamination risk while maintaining ease of assembly. Each segment can be independently positioned and connected without requiring penetration of the complete electrode structure.
2Ease of manufacture
If stacking-type bipolar batteries are used, then assembly process is simplified, but internal short-circuit risk increases due to blocker failure
Solution Approach 1:
The blocker material is extracted from the traditional stacking position and integrated into the folded structure itself. The folded portions of the bipolar electrode naturally create isolation zones between adjacent electrodes, eliminating the need for separate blocker components and reducing the risk of short-circuits associated with blocker failure.
3Volume of stationary object
If wound-typed bipolar batteries are used, then space utilization improves, but pressure uniformity on electrodes deteriorates
Solution Approach 1:
The bipolar electrode is folded into a curved S-shaped configuration rather than a linear or wound structure. This curvature allows the electrode to fit efficiently within the battery container volume while distributing mechanical pressure more uniformly across the electrode surfaces during compression, avoiding the non-uniform pressure issues associated with wound structures.
4Ease of manufacture
If conventional bipolar batteries with tabs and busbars are used, then electrical connection is simplified, but space utilization and energy density deteriorate
Solution Approach 1:
The electrical connection function is merged directly into the folded electrode structure itself. The folded portions of the bipolar electrode create direct electrical contact between adjacent electrodes at the folded sections, eliminating the need for separate tabs and busbars. This integration significantly improves space utilization and energy density while maintaining straightforward electrical connectivity.
Data Source
AI summary
A battery system comprises N folded bipolar batteries folded in an “S”-shaped configuration. First and second folded portions of each of the N folded bipolar batteries are arranged on opposite ends of the “S”-shaped configuration. First side portions and second side portions of each of the N folded bipolar batteries are arranged between the first and second folded portions. One or more of the first folded portions on a first one of the N folded bipolar batteries are in direct electrical contact with one or more of the second folded portions on a second one of the N folded bipolar batteries. One or more of the first side portions on a third one of the N folded bipolar batteries are in direct electrical contact with one or more of the second side portions on a fourth one of the N folded bipolar batteries.