Planar Electrode Substrate Thermal Expansion Isolation

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Solution Overview

Problem

Existing battery configurations with stacked electrochemical cells face manufacturing challenges, require complex and costly connections, and are prone to thermal runaway due to short circuits, which can lead to performance deterioration and safety hazards.

Innovation Solution

The configuration includes a substrate with discrete electrode segments and a current collector bus, where the substrate's volume change, induced by heating, electronically isolates problematic electrodes from the current collector bus, and integrated heaters or sensors monitor temperature and pressure to prevent overheating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If stacked arrangement of multiple discrete electrochemical cells is used, then battery capacity and energy storage are improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvebattery capacityVSAvoidmanufacturing complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

Multiple electrochemical cells are merged into a single planar structure where multiple anodes and cathodes are arranged in parallel on one substrate, eliminating the need for separate stacked cells and reducing manufacturing complexity while maintaining high capacity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery structure transitions from a three-dimensional stacked arrangement to a two-dimensional planar configuration, allowing multiple electrode layers to be integrated in a single plane with simplified assembly and manufacturing processes

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If stacked arrangement with multiple discrete cells is used, then battery capacity is improved, but electrical connection complexity increases

Engineering Contradiction:

Improvebattery capacityVSAvoidelectrical connection complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

Multiple current collectors are merged into a single current collector bus that electrically connects all electrode segments simultaneously, reducing the number of separate electrical connections required and simplifying the overall electrical architecture

Inventive Principle:

Principle #5Merging (Combining)

3Quantity of substance

If individual electrodes are closely arranged in stacked configuration, then energy density is improved, but thermal runaway propagation risk increases

Engineering Contradiction:

Improveenergy densityVSAvoidthermal runaway propagation

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The battery is segmented into multiple independently isolatable electrode modules on a single substrate, allowing faulty segments to be electrically isolated from healthy ones, preventing thermal runaway propagation while maintaining high energy density through compact arrangement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A substrate acts as an intermediary between multiple electrode layers, providing both structural support and thermal management functionality that reduces thermal runaway propagation risk while enabling high energy density through efficient space utilization

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If heaters and sensors are integrated into the battery structure, then temperature monitoring and control capability are improved, but device complexity increases

Engineering Contradiction:

Improvetemperature monitoring capabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Heaters and sensors are merged into the existing substrate and electrode structure, utilizing the same structural components for multiple functions (structural support, thermal management, and monitoring) rather than adding separate dedicated systems, thereby improving reliability without significantly increasing complexity

Inventive Principle:

Principle #5Merging (Combining)

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 configuration simplifies manufacturing, reduces costs, and enhances safety by automatically isolating faulty electrodes, preventing thermal runaway and maintaining battery performance.

Implementation Method 1

heating at least a portion of an electrochemical device using a heater that is a part of the electrochemical device

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the substrate's volume change, induced by heating, electronically isolates problematic electrodes from the current collector bus

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

the one or more sensors is configured to respond to a condition of the article

Methodology Applied

Scientific EffectTemperature sensing: Thermocouple

Data Source

PatentUS11637353B2Electrodes, heaters, sensors, and associated articles and methods

Publication Date: 2023.04.25 SION POWER CORP

AI summary

Articles and electrochemical devices containing electrodes, current collectors, heaters, and/or sensors and associated systems and methods, are provided. The sensors, when present, may be temperature sensors or pressure sensors. In some cases, the heaters and/or sensors are adjacent to the article or electrochemical device. In certain cases, the heaters and/or sensors are thin films that are integrated into the article or electrochemical device.