Reinforced Bipolar Battery End Plates for Uniform Electrolyte Filling
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Solution Overview
Problem
Bipolar battery assemblies face challenges in efficiently filling with liquid electrolyte while maintaining a seal, particularly when using a single port for both vacuum creation and filling, which can lead to internal forces causing deformation of electrode plates, resulting in non-uniform filling and potential leakage.
Innovation Solution
The use of reinforced end plates with internal structures attached around both the periphery and inner surfaces of the end plates, providing a stiffness of at least 400 ksi, which helps resist both outward and inward deformations during vacuum creation and filling, allowing for uniform electrolyte distribution and maintenance of a seal using a single port.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single port is used for both vacuum creation and electrolyte filling, then device complexity is reduced, but internal forces cause deformation of electrode plates resulting in non-uniform filling
Solution Approach 1:
The end plate is segmented into multiple functional zones: a peripheral sealing region, an internal reinforcement structure, and a vacuum port region. This segmentation allows the single port to perform vacuum creation while the reinforced structure independently manages internal forces, preventing deformation and ensuring uniform electrolyte distribution.
Solution Approach 2:
The solution moves from a two-dimensional flat end plate to a three-dimensional structure with internal reinforcement elements extending into the battery assembly. This adds structural depth that provides rigidity and resistance to internal forces during vacuum creation, preventing electrode plate deformation while maintaining a single-port configuration.
2Strength
If end plates are made heavier to resist deformation, then structural strength is improved, but overall battery weight increases
Solution Approach 1:
The end plate employs a composite structure combining a base plate material with internal reinforcement elements of different material properties. This composite design provides enhanced strength and rigidity to resist deformation during vacuum creation and operation, while the distributed reinforcement allows for optimized weight compared to a uniformly thick heavy plate.
Solution Approach 2:
Instead of increasing weight through uniform thickness, the solution adds structural capability in the third dimension with internal reinforcement elements. This provides the necessary strength and rigidity to resist deformation while maintaining lower overall weight compared to a solid heavy plate design.
3Productivity
If vacuum filling is performed quickly to improve productivity, then fill time is reduced, but air pockets may form between electrode plate layers
Solution Approach 1:
The internal reinforcement structure is pre-configured to maintain the spatial configuration and gaps between electrode plates before vacuum filling begins. This preliminary structural preparation ensures that electrolyte can flow uniformly through all channels during rapid filling, preventing air pocket formation even at high fill rates.
Solution Approach 2:
The reinforced end plate structure modifies the physical parameters of the battery assembly by maintaining consistent gaps and pressure distribution during vacuum filling. This structural control allows rapid electrolyte introduction while preventing air entrapment, enabling high productivity without compromising reliability.
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 reinforced end plates effectively distribute internal loads from vacuum pressures, preventing deformation and ensuring uniform filling of electrolyte within the battery assembly, thereby maintaining a seal and reducing the risk of leakage, even under varying operational pressures.
Implementation Method 1
filling a battery assembly with a liquid electrolyte under a vacuum
Implementation Method 2
an electrolyte may be able to be drawn into the individual electrochemical cells
Data Source
AI summary
An article having (a) one or more stacks of a plurality of electrode plates include: (i) one or more bipolar plates having a substrate having an anode on one surface and a cathode on an opposing surface; (ii) a separator and a liquid electrolyte located between each of the electrode plates; (b) a first end plate having a first end plate internal reinforcement structure, attached at an end of the one or more stacks; (c) a second end plate having a second end plate internal reinforcement structure, attached at an opposing end of the one or more stacks as the first end plate; wherein the first end plate and the second end plate reinforce the plurality of electrode plates during a charge cycle, a discharge cycle, or both the charge cycle and the discharge cycle.