Polymer Frame Support for EV Battery Cell Manufacturing
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Solution Overview
Problem
Existing battery manufacturing methods face challenges in handling and assembling battery components, particularly with brittle electrolyte materials and in ensuring mechanical stability, especially at the battery cell edges.
Innovation Solution
The method involves unrolling a polymer foil, forming windows to create a polymer frame, and placing a battery cell component over the window, which can be connected to a separator or bipolar current collector via gluing, welding, or friction fit, allowing for easy handling and assembly, and using solid-state electrolytes as separators to enhance mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional battery manufacturing methods are used without polymer frame support, then the manufacturing process is simpler, but the mechanical stability of the battery cell edges deteriorates
Solution Approach 1:
The battery cell is divided into distinct components with the polymer frame acting as a separate structural element that provides mechanical support to the edges of the battery cell, thereby improving stability without complicating the overall manufacturing process
Solution Approach 2:
The polymer frame serves as an intermediary component between the battery electrodes and the external environment, providing mechanical protection and structural support while allowing the manufacturing process to remain relatively simple through standard assembly techniques
2Ease of operation
If brittle electrolyte materials are used without protective framing, then the battery can be manufactured with fewer components, but the handling and assembly difficulty increases
Solution Approach 1:
A polymer frame with a flexible yet structurally sound design is used to protect the brittle electrolyte materials, providing easy handling through the frame's inherent flexibility while maintaining protection against damage during assembly and operation
Solution Approach 2:
The polymer frame provides beforehand cushioning and protection for the brittle electrolyte materials, preventing damage before it can occur during handling and assembly operations, thereby improving ease of operation without significantly increasing component complexity
3Reliability
If polymer frame support is added to battery cells, then the mechanical stability and vibration resistance improve, but the manufacturing process becomes more complex
Solution Approach 1:
The polymer frame is designed as a separate, modular component that can be manufactured independently and then assembled to the battery cell, improving vibration resistance while maintaining manufacturing ease through standardized assembly processes
Solution Approach 2:
The polymer frame serves multiple functions including mechanical support, vibration damping, and structural protection, thereby improving reliability without proportionally increasing manufacturing complexity since a single component performs multiple protective roles
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 simplifies the manufacturing process, provides enhanced mechanical stability, and facilitates the separation of anode and cathode compartments, enabling easier handling of brittle electrolyte materials and improving the resilience of battery components against vibrations.
Implementation Method 1
The polymer frame preferably is connected to either a separator or a bipolar current collector of the battery cell component, via for example an attachment with gluing, welding, heat bonding, lamination or with an additional adhesive tape to the separator, or via a friction fit.
Data Source
AI summary
A method for manufacturing a battery component includes unrolling a polymer foil from a roll; forming windows into the unrolled polymer foil; and placing a battery cell component over each window. The battery cell component advantageously can be a solid-state electrolyte functioning as a separator, which is thereby well protected for handling and in later use.