Zigzag Bipolar Electrode Design for High-Output Battery Packs
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Solution Overview
Problem
Bipolar batteries face challenges in achieving high energy density and output due to the integration of positive and negative poles, which leads to short circuits and increased internal resistance when spirally wound, and the use of liquid electrolytes limits their scalability.
Innovation Solution
A non-aqueous electrolyte battery design featuring a zigzag-shaped bipolar electrode with separate positive and negative active material layers on either side of a current collector, divided and alternately bent to prevent short circuits, and a gelled electrolyte to enhance ion conductivity, along with strategically placed current collection tabs to reduce resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If bipolar electrodes are laminated in series to obtain high voltage, then output is improved, but the structure becomes complex and requires prevention of liquid electrolyte contact between layers
Solution Approach 1:
The bipolar electrode is divided into multiple electrode bodies, each comprising a current collector with positive-pole and negative-pole active material layers. These electrode bodies are laminated in series with electrolyte layers interposed between them, allowing high voltage and output while maintaining modular structure that simplifies electrolyte management.
Solution Approach 2:
A polymer electrolyte membrane is introduced as an intermediary layer between adjacent electrode bodies. This membrane allows ionic conduction while preventing direct contact between liquid electrolytes from different layers, thereby eliminating short circuit risks while maintaining the series lamination structure for high output.
2Reliability
If polymer solid electrolyte is used to prevent short circuit, then reliability is improved, but ion conductance decreases significantly
Solution Approach 1:
A composite electrolyte system is employed consisting of a polymer electrolyte membrane (providing structural integrity and short circuit prevention) combined with gelled electrolyte (providing high ion conductance). The gelled electrolyte is formed by impregnating a porous gelator with liquid electrolyte, creating a semi-solidified structure that maintains high ion conductivity while preventing direct liquid contact between layers.
3Power
If gelled electrolyte is used to maintain high ion conductance, then power is improved, but manufacturing complexity increases
Solution Approach 1:
The gelator is pre-formed into a porous structure with controlled pore size and distribution before electrolyte impregnation. This preliminary preparation ensures uniform electrolyte distribution and consistent gel structure, simplifying the subsequent impregnation process and improving manufacturing reproducibility while maintaining high ion conductance.
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 design allows for a high energy density and low resistance, enabling a compact, high-output battery pack with improved sealing and reduced internal resistance, suitable for applications requiring large current characteristics.
Implementation Method 1
an ion conductance of the solid electrolyte is generally much lower than that of the liquid electrolyte and is about 1/10 to 1/100 of that of the liquid electrolyte
Data Source
AI summary
A non-aqueous electrolyte battery includes a bipolar electrode and a non-aqueous electrolyte. The electrode includes positive-pole and negative-pole active material layers formed on both side surfaces of a current collector. The electrode is divided into plural parts each having a predetermined length in one direction, and is sequentially and alternately bent at every lines between the parts in opposite directions so that the parts are overlapped with each other.