DESC:TECHNICAL FIELD
The present disclosure relates generally to the field of battery technology and more specifically, to a bipolar battery device (e.g., an advanced Bipolar Zinc-based battery for energy storage applications).
BACKGROUND
Currently, different types of batteries are used depending on an application. Some examples of different types of batteries are li-ion batteries, lead-acid batteries, alkaline batteries, Nickel-cadmium (NiCd) batteries, Zinc-based batteries and the like. A conventional battery device includes one or more electrochemical cells and an electrolyte. Each electrochemical cell includes a positive electrode and a negative electrode, which exchange ions with the electrolyte to generate electric power. Bipolar batteries are used in variety of applications due to advantages such as low weight, and long-life cycle as compared to other types of batteries. The bipolar battery is a type of rechargeable battery in which each electrochemical cell is made up of a current collector with the positive electrode on one surface of the current collector and the negative electrode on another surface of the current collector. Further, such multiple electrochemical cells are assembled to form the bipolar battery. However, the problem with the conventional bipolar batteries is that the assembly of the electrochemical cells in the bipolar batteries is quite complex and not adequately impervious to the liquid electrolyte, i.e., there is a risk of leakage of the liquid electrolyte through one or more gaps in between consecutive electrochemical cells. Further, loose contact between consecutive electrochemical cells may lead to occurrence of power loss in the conventional bipolar battery.
Currently, certain attempts have been made to solve the problem of electrolyte leakage and power losses. Such conventional attempts include use of one or more sealants or sealing blocks, which usually surround the positive electrodes, negatives electrodes and the current collectors in each electrochemical cell. Another conventional attempts include use of glue or adhesives to attach different components around conventional current collector. The glue or adhesives in the conventional bipolar batteries can react chemically with the liquid electrolyte, which may interfere with overall battery chemistry and may even result in reducing battery life, or damage to the conventional bipolar batteries. Furthermore, there is a possibility of melting or deterioration of the glue or adhesive due to repeated heat generation during operation of the bipolar battery device and cause separation of components in the bipolar battery due to prolonged operation. Furthermore, the conventional bipolar batteries are complex to manufacture and assemble due to the technical problems of leakage and power losses. Thus, there exist a technical problem of how to increase operational life of a battery device, reduce complexity in assembly of battery components, and at the same time avoid use of glue or sealants without any compromise in handling of electrolyte leakage and power losses.
Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional bipolar battery devices.
SUMMARY
The present disclosure provides a bipolar battery device (e.g., an advanced Bipolar Zinc-based battery for energy storage applications, for example, for use in electric vehicles (EVs), Micro grid, Stationary energy storage etc.). The present disclosure provides a solution to the technical problem of how to increase operational life of a bipolar battery device, reduce complexity in assembly of battery components, and at the same time avoid use of glue or sealants without any compromise in handling of electrolyte leakage and power losses. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in prior art and provide an improved bipolar battery device that avoids use of glue or sealants around a current collector layer, and provides an integrated non-conducting frame having two-subframes that sandwiches the current collector layer without any use of additional glue, adhesives, sealants, or sealing blocks around the current collector layer, thereby reducing complexity in assembly of battery components, and preventing any adverse chemical reaction that could have occurred if any glue, adhesive, or sealants were used.
One or more objectives of the present disclosure is achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
In one aspect, the present disclosure provides a bipolar battery device. The bipolar battery device comprises a plurality of cell layers. The plurality of cell layers comprises a first non-conducting frame having two sub-frames that are structurally complementary to each other and a first metallic current collector layer sandwiched between the two sub-frames that are joinable devoid of any glue or additional sealing blocks to form a first integrated non-conducting frame such that edges of the first metallic current collector layer are surrounded by the first integrated non-conducting frame. Further, the bipolar battery device further comprises a first anode layer disposed on a first side of the first metallic current collector layer and a first cathode layer disposed on a second side of the first metallic current collector layer. Moreover, the first anode layer and the first cathode layer come in direct contact with middle conductive portions of the first metallic current collector layer when an external force is applied to compress the plurality of cell layers during assembly of the bipolar battery device.
The bipolar battery device provides an integrated non-conducting frame having two-subframes that sandwiches the first current collector layer without any use of additional glue, adhesives, sealants, or sealing blocks around the current collector layer, which is beneficial to prevent any adverse chemical reaction that could have occurred if any glue, adhesive, or sealants were used. Furthermore, the improved bipolar battery device includes lesser number of components (e.g., less number of current collectors) as compared to conventional bipolar battery devices, which is beneficial to reduce complexity in assembly of battery components and reduce material cost during manufacturing of the improved bipolar battery device. In addition, the improved bipolar battery device is beneficial to prevent chemical reaction between the glue or adhesive and the liquid electrolyte and improves the operational life of the disclosed bipolar battery device. Furthermore, due to absence of glue or adhesive, the separation of the current collectors from the two sub-frames due to repeated heat generation during prolonged operation of the improved bipolar battery device can be avoided as compared to conventional bipolar batteries (which involves use of glue or adhesives for attaching the current collectors to one or more frames).
In an implementation, the plurality of cell layers further comprises a second non-conducting frame having two sub-frames that are structurally complementary to each other. Furthermore, the plurality of cell layers comprises a second metallic current collector layer sandwiched between the two sub-frames that are joinable devoid of any glue or additional sealing blocks to form a second integrated non-conducting frame such that edges of the second metallic current collector layer are surrounded by the second integrated non-conducting frame. Moreover, the plurality of cell layers comprises a separator layer disposed between the first anode layer and a second cathode layer and the second cathode layer disposed between the separator layer and a second side of the second non-conducting frame.
In addition to the first non-conducting frame, there is also provided the second non-conducting frame. Such arrangement of the non-conducting frames along with the separator layer interposed between the first anode layer and the second cathode layer is advantageous, to not only prevent short-circuit in the bipolar battery device by preventing direct contact between the first anode layer and the second cathode layer as an inherent benefit, but also to provide a compact form factor to the bipolar battery device and simplify the assembly process.
In an implementation, each of the first non-conducting frame and the second non-conducting frame comprises one or more liquid electrolyte filling slots at one end.
The liquid electrolyte filling slots in the first non-conducting frame and the second non-conducting frame provide a narrow passage for pouring the liquid electrolyte between two cell layers in the disclosed bipolar battery device, which reduces wastage of the liquid electrolyte due to leakage or due to overflow and provides a convenient medium for transfer of the liquid electrolyte into the bipolar battery device.
In an implementation, the bipolar battery device is a Zinc-based bipolar battery and a liquid electrolyte filled in the bipolar battery device via the one or more liquid electrolyte filling slots is an aqueous electrolyte suited for the Zinc-based bipolar battery.
Unlike the conventional Li-ion or other types of conventional battery devices, as the disclosed bipolar battery device is the Zinc gel bipolar battery, it is nontoxic, non-flammable and it is a fully recyclable battery. The placement of the one or more liquid electrolyte filling slots makes the electrolyte re-filling in the bipolar battery device convenient as and when the bipolar battery device becomes dry.
In a further implementation, the two sub-frames of the first non-conducting frame comprises a male energy line in one sub-frame and a female energy line in another sub-frame that are joined devoid of any glue or additional sealing blocks to form the first integrated non-conducting frame.
The male energy line and the female energy line in the two sub-frames of the first non-conducting frame becomes engaged with each other and thus are beneficial to facilitate joining of the two sub-frames that accommodates the first metallic current collector layer therebetween, thereby preventing the separation of the first metallic current collector layer from the first non-conducting frame during prolonged operation of the bipolar battery device.
In a further implementation, the first metallic current collector layer has a metallic projection protruding from the first integrated non-conducting frame, and wherein the metallic projection is connected to a battery management system (BMS) to establish a communication between the bipolar battery device and the BMS to control the bipolar battery device.
The metallic projection from the first integrated non-conducting frame can be connected to BMS, which is turn enables efficient control of the disclosed bipolar battery device by the BMS.
In a further implementation, the metallic projection protruding from the first integrated non-conducting frame is positioned along a first plane that is different from a second plane when placing a second integrated non-conducting frame along with other metallic projection adjacent to the first integrated non-conducting frame to avoid contact of two consecutive metallic projections.
Beneficially, the positioning of the different metallic projections lying adjacent to each other in the disclosed bipolar battery device prevents damage due to short circuit in the bipolar battery device by preventing contact between two consecutive metallic projections.
In a further implementation, the bipolar battery device comprises a first base plate, a first metallic positive terminal plate, a second base plate and a second metallic negative terminal plate. Moreover, the first base plate, the first metallic terminal plate, the plurality of cell layers, the second metallic terminal plate and the second base plate are arranged in a sequence.
In a further implementation, the plurality of cell layers that lies between the first base plate and the second base plate are compressed by screwing the two base plates, and wherein the compression in a range of 20-80 kg/cm2.
The compression of the plurality of cell layers during the assembly of the improved bipolar battery device is beneficial to maintain a close contact between the plurality of cell layers to improve current efficiency of the bipolar battery device of the present disclosure.
In a further implementation, during compression of the plurality of cell layers that lies between the first base plate and the second base plate, voltages corresponding to each cell of the plurality of cell layers get added due to a physical contact between the first anode layer, the first metallic current collector layer, the first cathode layer and a presence of the liquid electrolyte that diffuses among in the plurality of cell layers.
It is to be appreciated that all the aforementioned implementations can be combined. Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1A is a diagram illustrating a prior art that depicts side view of a conventional current collector glued to a conventional sealing frame in a conventional bipolar battery device.
FIG. 2A is a diagram illustrating a metallic current collector layer sandwiched in an integrated non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure;
FIG. 2B is a diagram illustrating electrode layers and a non-conducting frame of a bipolar battery device, in accordance with another embodiment of the present disclosure;
FIG. 2C is a diagram illustrating a sectional side view of an integrated non-conducting frame of a bipolar battery device, in accordance with another embodiment of the present disclosure;
FIG. 3 is a diagram that depicts a schematic exploded view of electrode layers, a separator layer and two non-conducting frames of a bipolar battery device, in accordance with another embodiment of the present disclosure;
FIG. 4A is a diagram that depicts a male energy line over one sub-frame out of the two sub-frames of a non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure;
FIG. 4B is a diagram that depicts a female energy line over one sub-frame out of the two sub-frames of a non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure;
FIG. 5A is a diagram that depicts a liquid electrolyte filling slot in non-conducting frames of a bipolar battery device, in accordance with another embodiment of the present disclosure;
FIG. 5B is a diagram that depicts a detailed view of a liquid electrolyte filling slots in non-conducting frames of a bipolar battery device, in accordance with another embodiment of the present disclosure;
FIG. 6A is a diagram that depicts a sealing cap configured over a non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure;
FIG. 6B is a diagram that depicts a schematic exploded view of a sealing cap configured over a non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure; and
FIG. 7 is a diagram that depicts a schematic assembled view of a bipolar battery device, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
FIG. 1 is a diagram illustrating a prior art that depicts side view of a conventional current collector glued to a conventional sealing frame in a conventional bipolar battery device. With reference to FIG. 1, there is shown a diagram that depicts a side view 100 of a conventional current collector 102 glued to a conventional sealing frame 104 in a conventional bipolar battery device. In this case, the conventional current collector 102 is attached with the conventional sealing frame 104 with the help of a glue 106 or adhesive to make a permanent contact between the conventional current collector 102 and the conventional sealing frame 104. The technical problem with the use of the glue 106 (or adhesive or sealant) is that the glue 106 reacts with an electrolyte present in the conventional bipolar battery device, which may result in damage to the conventional bipolar battery device. Further, glue 106 (or adhesive or sealant) used in the conventional bipolar battery device is susceptible to high temperature and can result in its melting or deterioration due to repeated heat generation during operation of the conventional bipolar battery device. Due to deterioration of the glue 106 (or adhesive or sealant), there is a possibility of separation of the conventional current collector 102 from the conventional sealing frame 104, which can result in lowering the current efficiency of the conventional bipolar battery device. In some conventional battery devices, three separate components (e.g., sealing blocks and frame components) are used to form a sealing around the conventional current collector, which is not beneficial due to requirement of a large number of components for manufacturing of a conventional bipolar battery device and increase in material cost. Moreover, such three separate components may be again joined using adhesives and sealants, which is not desirable.
FIG. 2A is a diagram illustrating a metallic current collector layer sandwiched in an integrated non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 2A, there is shown a bipolar battery device 202 that comprises a plurality of cell layers 204. The plurality of cell layers 204 comprises a first non-conducting frame 206A having two sub-frames 208A and 210A that are structurally complementary to each other. The plurality of cell layers 204 are arranged in a sequence in close contact with each other.
In an implementation, the plurality of cell layers 204 are in a form of thin layers arranged in contact with each other. The number of cell layers in the plurality of cell layers 204 is determined based on output voltage requirement. In an implementation, the two sub-frames 208A and 210A of the first non-conducting frame 206A are hollow frames made up of an electrically non-conducting material and surrounds the first metallic current collector layer 212A at its boundaries (peripheral regions). Examples of the non-conducting material used in the first non-conducting frame 206A and other non-conducting frames include, but are not limited to, high density polyethylene (HDPE), nylon, polyvinyl chloride, and the like.
In an implementation, the two sub-frames 208A and 210A of the first conducting frame 206A are manufactured by injection moulding. Further, the plurality of cells layers 204A in the bipolar battery device 202 include a first metallic current collector layer 212A sandwiched between the two sub-frames 208A and 210A of the first non-conducting frame 206A. In an implementation, the first metallic current collector layer 212A is a conductive (metallic) plate, which acts as a medium for transfer of electrons from within the bipolar battery device 202 to an external circuit connected to the bipolar battery device 202. Due to sandwiching the first metallic current collector layer 212A between the two sub-frames 208A and 210A of the first non-conducting frame 206A, the first metallic current collector layer 212A acquires mechanical strength to support other layers, like the anode and cathode layers and separators etc. to withstand compression at the time of assembly of the bipolar battery device 202.
The two sub-frames 208A and 210A of the first non-conducting frame 206A are joinable with each other devoid of any glue or additional sealing blocks to form a first integrated non-conducting frame such that edges of the first metallic current collector layer 212A are surrounded by the first integrated non-conducting frame. In an implementation, during assembly of the bipolar battery device 202, the two sub-frames 208A and 210A of the first non-conducting frame 206A are heat pressed. Further, the first metallic current collector layer 212A is placed over the one sub frame out of the two sub-frames 208A and 210A and another sub-frame out of the two sub-frames 208A and 210A is fitted over the first metallic current collector layer 212A. Furthermore, an external pressure is applied over the two sub-frames 208A and 210A in order to sandwich the first metallic current collector layer 212A between the two sub-frames 208A and 210A of the first non-conducting frame 206A. In another implementation, the first metallic current collector layer 212A is fitted in between the two sub frames 208A and 210A of the first non-conducting frame 206A during injection moulding of the first non-conducting frame 206A. In yet another implementation, the two sub-frames 208A and 210A of the first non-conducting frame 206A are joined together by ultra violet (UV) sealing method.
In such implementation, there is no use of any glue or additional sealing blocks during joining of the two sub-frames 208A and 210A of the first non-conducting frame 206A to form the first integrated non-conducting frame. Therefore, the joint between the two sub-frames 208A and 210A of the first non-conducting frame 206A is almost non-separable (i.e., can only be separated by destruction of the first non-conducting frame 206A) and maintain the assembly of the two sub-frames 208A and 210A of the first non-conducting frame 206A and the first metallic current collector layer 212A during prolonged operation of the bipolar battery device 202, which is advantageous over conventional bipolar battery devices, which use glue or adhesives during assembly of the battery components.
Furthermore, with reference to FIG. 2A, there is shown a metallic projection 214A, which is extending from the first integrated non-conducting frame. The metallic projection 214A is a part of the first metallic current collector layer 212A. The metallic projection 214A is connected to a battery management system (BMS) (not shown) to establish a communication between the bipolar battery device 102 and the BMS to control the bipolar battery device 202. The metallic projection 214A from the first integrated non-conducting frame enables efficient control of the disclosed bipolar battery device 102 by the BMS.
In an implementation, the first non-conducting frame 206A comprises a plurality of perforations 216A, along the periphery of the first non-conducting frame 206A. A definite number of perforations (e.g., a first set of perforations) out of the plurality of perforations 216A are used to attach two or more non-conducting frames. Optionally, some of the perforations (e.g., a second set of perforations) out of the plurality of perforations 216A in the first non-conducting frame 206A are engaged with a plurality of projections (not shown in FIGs) over an adjacent non-conducting frame to maintain a firm contact between two consecutive non-conducting frames. Furthermore, with reference to FIG. 2A, there are shown a plurality of troughs 218A provided over periphery of the first non-conducting frame 206A at one side. In case of contact of two consecutive non-conducting frames, one trough over the first non-conducting frame 206A and another trough over adjacent non-conducting frame forms an electrolyte filling slot. The electrolyte filling slot is configured to provide passage for entry of a liquid electrolyte into the bipolar battery device 202.
FIG. 2B is a diagram illustrating electrode layers and a non-conducting frame of a bipolar battery device, in accordance with another embodiment of the present disclosure. With reference to FIG. 2B, there is further shown a first anode layer 220A disposed on a first side 222A of the first metallic current collector layer 212A (of FIG. 2A) that is sandwiched between the two sub-frames 208A and 210A of the first non-conducting frame 206A. In an implementation, the first anode layer 222B is a positive electrode in the form of a thin layer in contact with the first side 222A of the first metallic current collector layer 212A. The first anode layer 202B is made of a material, which accepts negatively charged ions during operation of the bipolar battery device 202.
FIG. 2C is a diagram illustrating a sectional side view of an integrated non-conducting frame of a bipolar battery device, in accordance with another embodiment of the present disclosure. FIG. 2C is the sectional side view obtained after sectioning of the first non-conducting frame 206A along an X-X axis (as shown in FIG. 2B). With reference to FIG. 2C, there is further shown a first cathode layer 220B disposed on a second side 222B of the first metallic current collector layer 212A that is sandwiched between the two sub-frames 208A and 210A of the first non-conducting frame 206A. In an implementation, the first cathode layer 220B is a negative electrode in the form of a thin layer in contact with the second side 222B of the first metallic current collector layer 212A. The first cathode layer 220B is made of a material, which accepts positively charged ions during operation of the bipolar battery device 202.
The first anode layer 220A and the first cathode layer 220B exchange electrons with each other during operation of the bipolar battery device 202. Furthermore, the first metallic current collector layer 212A transfers the electric current generated due to movement of electrons to an external circuit connected to the bipolar battery device 202. The first anode layer 220A and the first cathode layer 220B come in direct contact with middle conductive portions of the first metallic current collector layer 212A when an external force is applied to compress the plurality of cell layers 204 during assembly of the bipolar battery device 202. The direct contact of the first anode layer 220A and the first cathode layer 220B with the middle conducting portions of the first metallic current collector layer 206A enables efficient generation of flow of electrons (i.e. electric current) by reducing any power loss due to gaps in between the first anode layer 220A and the first cathode layer 220B.
The bipolar battery device 202 provides an integrated non-conducting frame having two-subframes 208A and 210A that sandwiches the first current collector layer 212A without any use of additional glue, adhesives, sealants, or sealing blocks around the first current collector layer 212A, which prevents any adverse chemical reaction that could have occurred if any glue, adhesive, or sealants were used. Furthermore, the bipolar battery device 202 includes lesser number of components (e.g., lesser number of current collectors) as compared to conventional bipolar battery devices, which reduces complexity in assembly of battery components and reduce material cost during manufacturing of the bipolar battery device 202. In addition, the bipolar battery device 202 is beneficial to prevent chemical reaction between the glue or adhesive and the liquid electrolyte and improves the operational life of the bipolar battery device 202. Furthermore, due to absence of glue or adhesive, the separation of the first current collector layer 212A from the two sub-frames 208A and 210A due to repeated heat generation during prolonged operation of the bipolar battery device 202 can be avoided as compared to conventional bipolar batteries (which involves use of glue or adhesives for attaching the current collectors to one or more frames).
FIG. 3 is a diagram illustrating an exploded view including electrode layers, a separator layer and two non-conducting frames of a bipolar battery device, in accordance with another embodiment of the present disclosure. With reference to FIG. 3, there is shown an exploded view 300 that depicts the first non-conducting frame 206A, the first anode layer 220A, a separator layer 314, a second cathode layer 308 and a second non-conducting frame 302.
In accordance with an embodiment, the plurality of cell layers 204 (of FIG. 2A) further includes the second non-conducting frame 302 having two sub-frames 304 and 306 that are structurally complementary to each other. In an implementation, the two sub-frames 304 and 306 of the second non-conducting frame 302 are hollow frames made up of a non-conducting material similar to that of the first non-conducting frame 206A.
In accordance with an embodiment, a second metallic current collector layer 308 is sandwiched between the two sub-frames 304 and 306 that are joinable devoid of any glue or additional sealing blocks to form a second integrated non-conducting frame such that edges of the second metallic current collector layer 310 are surrounded by the second integrated non-conducting frame. In an implementation, the second metallic current collector layer 310 is a conductive (metallic) plate, which acts as a medium for transfer of electrons from within the bipolar battery device 202 to an external circuit connected to the bipolar battery device 202. The two sub-frames 304 and 306 of the second conducting frame 302 are joined together by heat pressing or injection moulding or ultra violet sealing methods. In such implementation, there is no use of any glue or additional sealing blocks during joining of the two sub-frames 304 and 306 of the second non-conducting frame 302 to form the second integrated non-conducting frame. Further, with reference to FIG. 3, there is shown a second metallic projection 312 extending from the second integrated non-conducting frame. In accordance with an embodiment, the metallic projection 214A (of FIG. 2A) protruding from the first integrated non-conducting frame is positioned along a first plane and the second metallic projection 312 protruding from the second integrated non-conducting frame is positioned along a second plane. The second plane is different from the first plane and both the first plane and the second plane are parallel to each other. The second integrated non-conducting frame is placed adjacent to the first integrated non-conducting frame to avoid contact of two consecutive metallic projections (i.e., the metallic projection 214A and the second metallic projection 312). The position of the metallic projection 214A and the second metallic projection 312 in the bipolar battery device 202 is beneficial to prevent damage due to short circuit in the bipolar battery device 202 by preventing contact between two consecutive metallic projections.
Further, the second cathode layer 308 is attached on a second side of the second non-conducting frame 302 and is in contact with a middle conductive portion of the second metallic current collector layer 310. Moreover, the separator layer 310 is disposed between the first anode layer 220A and the second cathode layer 306. In an implementation, the separator layer 314 is a thin, non-conductive material layer (e.g., Absorbed Glass Mat (AGM) layer) that is placed between the first anode layer 220A and the second cathode layer 308 to prevent direct electrical contact between the first anode layer 220A and the second cathode layer 308. Further, the second cathode layer 308 is disposed between the separator layer 310 and the second side of the second non-conducting frame 302.
During assembly of the bipolar battery device 202, the first integrated non-conducting frame 206A along with the first anode layer 220A, the first metallic current collector layer 212A and the first cathode layer 220B (from FIG. 2C) forms a first cell layer. Furthermore, the second integrated non-conducting frame 302 along with the second cathode layer 308 and the second metallic current collector layer 310 forms a second cell layer. The first cell layer and the second cell layer are compressed together with an external force to establish a close contact between the components of the first cell layer and the second cell layer. Further, such multiple cell layers (such as the first cell layer and the second cell layer) are arranged in close contact with each other during assembly of the bipolar battery device 202.
The arrangement of the first non-conducting frame 206A and the second non-conducting frame 302 along with the separator layer 314 interposed between the first anode layer 220A and the second cathode layer 308 is advantageous, to not only prevent short-circuit in the bipolar battery device 202 by preventing direct contact between the first anode layer 220A and the second cathode layer 308 as an inherent benefit, but also to provide a compact form factor to the bipolar battery device 202 and simplifies the assembly process.
FIG. 4A is a diagram that depicts a male energy line over one sub-frame out of the two sub-frames of a non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 4A, there is shown a portion of a sub-frame with a male energy line 402A. The sub-frame may be one of the two sub-frames 208A and 210A. The male energy line 402A is a protrusion disposed along peripheral portion of one sub-frame of the two sub-frames 208A and 210A of each non-conducting frames, such as the first non-conducting frame 206A.
FIG. 4B is a diagram that depicts a female energy line 402B over one sub-frame out of the two sub-frames of a non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 4B, there is shown a portion of a sub-frame with the female energy line 402B. The sub-frame may be another sub-frame of the two sub-frames 208A and 210A In an implementation, the female energy line 402B is a trough configured along peripheral portion of the other sub-frame of the two sub-frames 208A and 210A of the first non-conducting frame 206A to accommodate the male energy line 402A.
In an implementation, the female energy line 402B is a negative replica of the male energy line 402A. In an example, during assembly of the first integrated non-conducting frame, the male energy line 402A of one sub-frame 208A is inserted in the female energy line 402B of another sub-frame 210A of the first non-conducting frame 206A so that the first metallic current collector layer 212A (of FIG. 2A) is sandwiched between the two sub-frames 208A and 210A of the first non-conducting frame 206A. The male energy line 402A and the female energy line 402B are beneficial to firmly join the two sub-frames 208A and 210A while sandwiching the first metallic current collector layer 212A, thereby preventing the separation of the first metallic current collector layer 212A from the first non-conducting frame 206A during prolonged operation of the bipolar battery device 202.
In an implementation, the plurality of cell layers 204 comprises the first non-conducting frame 206A having two sub-frames (208A, 210A) that are structurally complementary to each other and the first metallic current collector layer 212A sandwiched between the two sub-frames (208A, 210A) that are joinable devoid of any glue or additional sealing blocks to form the first integrated non-conducting frame such that edges of the first metallic current collector layer 212A are surrounded by the first integrated non-conducting frame.
A portion of the sub-frame comprises the male energy line 402A. The sub-frame may be one of the two sub-frames. The male energy line 402A is the protrusion disposed along peripheral portion of one sub-frame of the two sub-frames of each non-conducting frames, such as the first non-conducting frame. Further, a portion of the sub-frame comprises the female energy line 402B. The sub-frame may be another sub-frame of the two sub-frames. The female energy line 402B is a trough configured along peripheral portion of the other sub-frame of the two sub-frames of the first non-conducting frame to accommodate the male energy line 402A. The male energy line 402A and the female energy line 402B are beneficial to firmly join the two sub-frames while sandwiching the first metallic current collector layer, thereby preventing the separation of the first metallic current collector layer from the first non-conducting frame during prolonged operation of the bipolar battery device.
FIG. 5A is a diagram that depicts a liquid electrolyte filling slot in non-conducting frames of a bipolar battery device, in accordance with another embodiment of the present disclosure. With reference to FIG. 5A, there is shown a diagram that depicts one or more liquid electrolyte filling slots 502A in each non-conducting frames, such as the first non-conducting frame 206A or the second non-conducting frame 302 of the bipolar battery device 202 (of FIG. 2A). In accordance with an embodiment, each of the first non-conducting frame 206A and the second non-conducting frame 302 includes the one or more liquid electrolyte filling slots 502A at one end. In an implementation, the one or more liquid electrolyte filling slots 502A are narrow slots, which are configured on outer periphery of the two sub-frames 208A and 210A of the first non-conducting frame 206A and the two sub-frames 304 and 306 of the second non-conducting frame 302. The one or more liquid electrolyte filling slots 502A provide a passage for entering the liquid electrolyte in the bipolar battery device 202. The one or more liquid electrolyte filling slots 502A in the first non-conducting frame 206A and the second non-conducting frame 302 provide a narrow passage for pouring the liquid electrolyte between two cell layers in the bipolar battery device 202, which reduces wastage of the liquid electrolyte due to overflow and provide a convenient medium for transfer of the liquid electrolyte into the bipolar battery device 202.
FIG. 5B is a diagram that depicts a detailed view of a liquid electrolyte filling slots in non-conducting frames of a bipolar battery device, in accordance with another embodiment of the present disclosure. With reference to FIG. 5B, there is shown a diagram that depicts a close up view of the one or more liquid electrolyte filling slots 502A of the FIG. 5A.
FIG. 6A is a diagram that depicts a sealing cap configured over a non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 6A, there is shown a portion of a non-conducting frame (e.g., the first non-conducting frame 206A and the second non-conducting frame 302) with one or more electrolyte sealing caps 602A in a closed position 600A covering the one or more liquid electrolyte filling slots 502A (of FIG. 5A). In an implementation, the one or more electrolyte sealing caps 602A are pluggable and insertable over the one or more liquid electrolyte filling slots 502A after filling the liquid electrolyte in the bipolar battery device 202. The one or more electrolyte sealing caps 602A prevent leakage of the liquid electrolyte during operation of the bipolar battery device 202. In an implementation, the electrolyte sealing caps are made up of a non-conductive material such as high-density polyethylene (HDPE), nylon, polyvinylchloride (PVC) and the like.
FIG. 6B is a diagram that depicts a sealing cap in an open position configured over a non-conducting frame of a bipolar battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 6B, there is shown the portion 600A of the non-conducting frame (e.g., the first non-conducting frame 206A and the second non-conducting frame 302) with one or more electrolyte sealing caps 602A in an open position 600B.
FIG. 7 is a diagram illustrating a schematic assembled view of a bipolar battery device, in accordance with an embodiment of the present disclosure. With reference to FIG. 7, there is shown an assembled view 700 of the bipolar battery device 202 (of FIG. 2A).
In accordance with an embodiment, the bipolar battery device 202 includes a first base plate 702, a first metallic positive terminal plate 704, a second base plate 706 and a second metallic negative terminal plate 708. Moreover, the first base plate 702, the first metallic terminal plate 704, the plurality of cell layers 204 (of FIG. 2A), the second metallic negative terminal plate 708 and the second base plate 706 are arranged in a sequence. In an implementation, the first base plate 702 and the second base plate 706 are non-conducting plates arranged at end portions of the bipolar battery device 202 and provide support as well as protection to the bipolar battery device 202 from any external impact. In another implementation, the first metallic positive terminal plate 704 and the second metallic negative terminal plate 708 are metallic plates which act as a positive terminal and a negative terminal of the bipolar battery device 202 respectively. In an implementation, the first metallic positive terminal plate 704 and the second metallic negative terminal plate 708 are adapted to connect with an external load and transfer electric current from the bipolar battery device 202 to the external load. In an implementation, the external load may be any device, component, or a machine which require the electric current for corresponding operations. In accordance with an embodiment, the plurality of cell layers 204 that lie between the first base plate 702 and the second base plate 706 are compressed by screwing the two base plates, where the compression is in a range of 20-80 kg/cm2. The first base plate 702, the first metallic positive terminal 704, the plurality of cell layers 204, the second metallic negative terminal 708 and the second base plate 706 are compressed and screwed together to form the bipolar battery device 202. The compression of the plurality of cell layers 204 in the range of 20-80 kg/cm2 enables improving the current capacity due to close contact between the plurality of cell layers 204 without any use of glue, sealants, or adhesives. In an example, the plurality of cell layers 204 are combined together to form a stack. Before compression of the plurality of cell layers 204, the length of the stack is X cm. After compression of the plurality of cell layers 204 between the range 20-80 kg/cm2, the length of the stack become Y cm, where the value of Y is lesser than X (i.e., the length of the plurality of cell layers 204 gets decreased due to compression).
In accordance with an embodiment, during compression of the plurality of cell layers 204 that lies between the first base plate 702 and the second base plate 706, voltages corresponding to each cell of the plurality of cell layers 204 get added due to a physical contact between the first anode layer 220A, the first metallic current collector layer 212A, the first cathode layer 308 and a presence of the liquid electrolyte that diffuses among in the plurality of cell layers 204. In an example, one cell layer of the plurality of cell layers 204 includes the first non-conducing frame 206A, the first metallic current collector layer 212A, the first anode layer 220A, the first cathode layer 220B and the liquid electrolyte in contact with the first anode layer 220A and the first cathode layer 220B. Due to exchange of ions between the liquid electrolyte, the first anode layer 220A and the first cathode layer 220B, a voltage is generated for each cell layer. Due to compression of the plurality of cell layers 204, voltages corresponding to each cell layer get added to up to a definite value of voltage according to requirement. In an implementation, during the assembly of the bipolar battery device 202, the first base plate 702, the first metallic positive terminal 704, the plurality of cell layers 204, the second metallic negative terminal 708 and the second base plate 706 are compressed together and a plurality of screws 710 are inserted through peripheral portions of each of the first base plate 702, the first metallic positive terminal 704, the plurality of cell layers 204, the second metallic negative terminal 708 and the second base plate 706. In an implementation, the plurality of screws 710 (in the form of metallic rods) are inserted through the plurality of perforations 216A (of FIG. 2A) of the first non-conducting frame 206A. The number of the plurality of cell layers 204 is determined based on required output voltage. In an example, each cell layer in the plurality of cell layers 204 generates a voltage of 1.6V. Therefore, adding 30 cell layers in the bipolar battery device 202 gives a total voltage of 48V. In another example, the number of cells or cell layers may range from 30-76 cells or cell layers. The number of cell layers in the plurality of cell layers 204 may vary capacity wise. In an implementation, the capacity of the bipolar battery device 102 may be in the range of 7-9Ah (ampere hour) when 30 cell layers are employed. In another implementation, the capacity of the bipolar battery device 102 may be in the range of 15-20Ah (ampere hour).
In an example, in the bipolar battery device 202, each anode layer (such as the first anode layer 220A), each cathode layer (such as the first cathode layer 220B) and each current collector layer (such as the first metallic current collector layer 212A) of the plurality of cell layers 204 are in contact with the liquid electrolyte. During operation of the bipolar battery device 202, a chemical reaction between each anode layer (such as the first anode layer 220A), each cathode layer (such as the first cathode layer 220B) and each current collector layer (such as the first metallic current collector layer 212A) of the plurality of cell layers 204 takes place, which causes generation of a flow of electrons (i.e., electric current) through the plurality of cell layers 204. Due to compression of the plurality of cell layers 204, there is a close contact between which eliminates power losses in the bipolar battery device 202 during generation of the flow of electrons through the plurality of cell layers 204 and increases efficiency of the bipolar battery device 202.
In accordance with an embodiment, the bipolar battery device 202 is a Zinc-based bipolar battery, such as a Zinc gel bipolar battery, and the liquid electrolyte filled in the bipolar battery device 202 via the one or more liquid electrolyte filling slots 502A is an aqueous electrolyte suited for the Zinc-based bipolar battery. Unlike the conventional Li-ion or other types of conventional battery device, as the bipolar battery device 202 is the Zinc-based bipolar battery, which is nontoxic, non-flammable and a fully recyclable battery. The placement of the one or more liquid electrolyte filling slots 502A makes the electrolyte re-filling in the bipolar battery device 202 simple as and when the bipolar battery device 202 becomes dry. As compared to conventional bipolar battery devices, the bipolar battery device 202 has a lower cost of production, the non-conductive frames are flexible and easy to accommodate the current collector and are compatible to different types of electrolyte without causing any adverse chemical reaction with the electrolytes, ensures increased energy and power density, and is reliable to use.
The present disclosure provides the integrated non-conducting frame having two-subframes that sandwiches the first current collector layer without any use of additional glue, adhesives, sealants, or sealing blocks around the current collector layer, which is beneficial to prevent any adverse chemical reaction that could have occurred if any glue, adhesive, or sealants were used. Furthermore, the improved bipolar battery device of the present disclosure includes lesser number of components (e.g., less number of current collectors) as compared to conventional bipolar battery devices, which is beneficial to reduce complexity in assembly of battery components and reduce material cost during manufacturing of the bipolar battery device of the present disclosure. In addition, the improved bipolar battery device is beneficial to prevent chemical reaction between the glue or adhesive and the liquid electrolyte and improves the operational life of the bipolar battery device. Furthermore, due to absence of glue or adhesive, the separation of the current collectors from the two sub-frames due to repeated heat generation during prolonged operation of the improved bipolar battery device can be avoided as compared to conventional bipolar batteries (which involves use of glue or adhesives for attaching the current collectors to one or more frames). In addition, the engagement between the male energy line 402A and the female energy line 402B creates a seamless electrical connection, which ensures that there is no loss or interruption of electrical current between the different cell layers and the metallic current collector.
Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.
,CLAIMS:CLAIMS
We claim:
1. A bipolar battery device (202), comprising:
a plurality of cell layers (204), wherein the plurality of cell layers (204) comprises:
a first non-conducting frame (206A) having two sub-frames (208A, 210A) that are structurally complementary to each other;
a first metallic current collector layer (212A) sandwiched between the two sub-frames (208A, 210A) that are joinable devoid of any glue or additional sealing blocks to form a first integrated non-conducting frame such that edges of the first metallic current collector layer (212A) are surrounded by the first integrated non-conducting frame; and
a first anode layer (220A) disposed on a first side (222A) of the first metallic current collector layer (212A) and a first cathode layer (220B) disposed on a second side (222B) of the first metallic current collector layer (212A), wherein the first anode layer (220A) and the first cathode layer (220B) come in direct contact with middle conductive portions of the first metallic current collector layer (212A) when an external force is applied to compress the plurality of cell layers (204) during assembly of the bipolar battery device (202).

2. The bipolar battery device (202) as claimed in claim 1, wherein the plurality of cell layers (204) further comprises:
a second non-conducting frame (302) having two sub-frames (304, 306) that are structurally complementary to each other;
a second metallic current collector layer (308) sandwiched between the two sub-frames (304, 306) that are joinable devoid of any glue or additional sealing blocks to form a second integrated non-conducting frame such that edges of the second metallic current collector layer (308) are surrounded by the second integrated non-conducting frame;
a separator layer (314) disposed between the first anode layer (220A) and a second cathode layer (308); and
the second cathode layer (308) disposed between the separator layer (314) and a second side of the second non-conducting frame (302).

3. The bipolar battery device (202) as claimed in claim 2, wherein each of the first non-conducting frame (206A) and the second non-conducting frame (302) comprises one or more liquid electrolyte filling slots at one end.

4. The bipolar battery device (202) as claimed in claim 1, wherein the bipolar battery device (202) is a Zinc-based bipolar battery and a liquid electrolyte filled in the bipolar battery device (202) via the one or more liquid electrolyte filling slots (502A) is an aqueous electrolyte suited for the Zinc-based bipolar battery.

5. The bipolar battery device (202) as claimed in claim 1, wherein the two sub-frames (208A, 210A) of the first non-conducting frame (206A) comprises a male energy line (402A) in one sub-frame and a female energy line (402B) in another sub-frame that are joined devoid of any glue or additional sealing blocks to form the first integrated non-conducting frame.

6. The bipolar battery device (202) as claimed in claim 1, wherein the first metallic current collector layer (212A) has a metallic projection protruding from the first integrated non-conducting frame, and wherein the metallic projection (214A) is connected to a battery management system (BMS) to establish a communication between the bipolar battery device (202) and the BMS to control the bipolar battery device (202).
7. The bipolar battery device (202) as claimed in claim 6, wherein the metallic projection (214A) protruding from the first integrated non-conducting frame is positioned along a first plane that is different from a second plane when placing a second integrated non-conducting frame along with other metallic projection adjacent to the first integrated non-conducting frame to avoid contact of two consecutive metallic projections.

8. The bipolar battery device (202) as claimed in claim 1, wherein the bipolar battery device (202) comprises a first base plate (702), a first metallic positive terminal plate (704), a second base plate (706), and a second metallic negative terminal plate (708),
wherein the first base plate (702), the first metallic positive terminal plate (704), the plurality of cell layers (204), the second metallic negative terminal plate (708) and the second base plate (706) are arranged in a sequence.

9. The bipolar battery device (202) as claimed in claim 8, wherein the plurality of cell layers (204) that lies between the first base plate (702) and the second base plate (706) are compressed by screwing the first base plate (702) and the second base plate (706), and wherein the compression in a range of 20-80 kg/cm2.

10. The bipolar battery device (202) as claimed in claim 9, wherein during compression of the plurality of cell layers (204) that lies between the first base plate (702) and the second base plate (706), voltages corresponding to each cell of the plurality of cell layers (204) get added due to a physical contact between the first anode layer (220A), the first metallic current collector layer (212A), the first cathode layer (220B), and a presence of the liquid electrolyte that diffuses among in the plurality of cell layers (204).