DE-102025141383-A1 - STRUCTURED BATTERY FOR A VEHICLE

DE102025141383A1DE 102025141383 A1DE102025141383 A1DE 102025141383A1DE-102025141383-A1

Abstract

A structural battery for an electric vehicle is provided in which a plurality of negative electrode layers, a plurality of electrolyte layers and a plurality of positive electrode layers are laminated successively from top to bottom, wherein the negative electrode layer and the positive electrode layer each contain a negative electrode and a positive electrode, wherein an electrode slurry layer is applied to both surfaces of a carbon fiber current collector layer, and the carbon fiber current collector layer is formed by impregnating an electrode slurry formed from the electrode slurry layer into an inner porous layer.

Inventors

Won Ki SONG

Assignees

HYUNDAI MOTOR COMPANY
KIA CORPORATION

Dates

Publication Date: 20260513
Application Date: 20251010
Priority Date: 20241111

Claims (20)

A structural battery for an electric vehicle, comprising: a plurality of negative electrode layers; a plurality of electrolyte layers; and a plurality of positive electrode layers, whereby: the plurality of negative electrode layers, the plurality of electrolyte layers, which are laminated successively from top to bottom to several positive electrode layers, a negative electrode layer from the plurality of negative electrode layers and a positive electrode layer from the plurality of positive electrode layers each contain a negative electrode and a positive electrode, wherein an electrode slurry layer is applied to both surfaces of a carbon fiber current collector layer, and the carbon fiber current collector layer is formed by impregnating an electrode slurry formed from the electrode slurry layer into an inner porous layer.
Structural battery according to Claim 1 , wherein: the carbon fiber current collector layer is designed to have an area extending further outwards than the electrode slurry layer.
Structural battery according to Claim 2 , wherein: an electrolyte layer of the plurality of electrolyte layers contains a solid electrolyte applied to the upper and lower surfaces of the electrode slurry layer.
Structural battery according to Claim 3 , wherein: the electrolyte layer is designed to extend to and coat the area of the carbon fiber current collector layer that extends further outwards than the electrode slurry layer.
Structural battery according to Claim 4 , wherein: the electrolyte layer is designed such that it extends to a first side surface of the electrode slurry layer and a second side surface of the carbon fiber current collector layer on the same vertical line as one side of the electrode slurry layer and coats it.
Structural battery according to Claim 1 , wherein: edge parts of the plurality of negative electrode layers and the plurality of positive electrode layers are impregnated and sealed with resin.
Structural battery according to Claim 6 , wherein: at an edge of a negative electrode layer of the plurality of negative electrode layers and a positive electrode layer of the plurality of positive electrode layers, a glass fiber insulating layer is provided with an area extending further outwards than the carbon fiber current collector layer.
Structural battery according to Claim 7 , wherein: an inner part of the glass fiber insulating layer is attached to an edge part of the carbon fiber current collector layer by a resin material.
Structural battery according to Claim 8 , wherein: a construction gap consisting of a space is formed between the fiberglass insulating layer at a location where the resin material is positioned and the electrode slurry layer.
Structural battery according to Claim 1 , wherein: the negative electrode is formed by applying a negative electrode slurry layer to both surfaces of the carbon fiber current collector layer, and the positive electrode is formed by applying a positive electrode slurry layer to both surfaces of the carbon fiber current collector layer.
Structural battery according to Claim 10 , wherein: the negative electrode slurry layer contains a negative electrode active material, a first binder and a first conductive agent, and the positive electrode slurry layer contains a positive electrode active material, a second binder and a second conductive agent.
Structural battery according to Claim 1 , wherein: a carbon fiber structural reinforcement layer is laminated onto an outer part of each of the outermost upper and lower negative electrode layers.
Structural battery according to Claim 12 , wherein: a pouch film is laminated between the outermost upper and lower negative electrode layers and the carbon fiber structural reinforcement layer.
Structural battery according to Claim 12 , wherein: a glass fiber structural reinforcement layer between the outer part of each of the outermost upper and lower negative electrode layers and the It is laminated with a carbon fiber structural reinforcement layer.
Structural battery for an electric vehicle, comprising: a negative electrode layer, comprising: a first carbon fiber current collector layer with a first upper surface and a first lower surface; and a first electrode slurry layer applied to the first upper surface and the first lower surface, the first carbon fiber current collector layer being formed by impregnating a first electrode slurry from the first electrode slurry layer into a first inner porous layer of the first carbon fiber current collector layer; an electrolyte layer; and a positive electrode layer, comprising: a second carbon fiber current collector layer with a second upper surface and a second lower surface; and a second electrode slurry layer applied to the second upper surface and the second lower surface, whereby the second carbon fiber current collector layer is formed by impregnating a second electrode slurry from the second electrode slurry layer into a second inner porous layer of the second carbon fiber current collector layer, whereby: the negative electrode layer, the electrolyte layer, and the positive electrode layer are successively laminated from a top to a bottom of the structural battery.
Structural battery according to Claim 15 , wherein: the first carbon fiber current collector layer is configured to have a first region extending further outwards than the first electrode slurry layer, and the second carbon fiber current collector layer is configured to have a second region extending further outwards than the second electrode slurry layer.
Structural battery according to Claim 15 , wherein the electrolyte layer comprises a solid electrolyte.
Structural battery according to Claim 15 , wherein: a first edge part of the negative electrode layer and a second edge part of the positive electrode layer are impregnated and sealed with resin.
Structural battery according to Claim 15 , wherein: the first electrode slurry layer comprises: a negative electrode active material; a first binder; and a first conductive agent, and the second electrode slurry layer comprises: a positive electrode active material; a second binder; and a second conductive agent.
Structural battery according to Claim 15 , wherein: a first glass fiber insulating layer with a first area extending further outwards than the first carbon fiber current collector layer is provided at a first edge of the negative electrode layer, and a second glass fiber insulating layer with a second area extending further outwards than the second carbon fiber current collector layer is provided at a second edge of the positive electrode layer.

Description

TECHNICAL AREA The disclosure relates to a structural battery for vehicles and in particular to a structural battery for electric vehicles, which can be used as part of a vehicle body to mechanically connect parts while being electrochemically connected to a lithium-ion battery to increase voltage. BACKGROUND In general, a lithium-ion battery attached to an electric vehicle takes up a considerable part of the vehicle's weight but does not perform any load-bearing function. In contrast, a structured battery is 500, as in 1 As shown, a component is installed in a frame or structure 800 that forms an electric vehicle 1000, and simultaneously performs the load-bearing, charging/discharging, and amplifying functions of a high-voltage battery 600 installed on a floor 700 of the vehicle body. In other words, the structural battery 500 can function as a battery and simultaneously fulfill the function of an electric vehicle structure. This battery is also known as a massless energy storage device because, when the battery's weight becomes part of the load-bearing structure, the weight of the energy-storing battery is practically non-existent. These composite batteries can significantly reduce the vehicle's weight. When structural batteries are used in electric vehicles, the weight can be reduced and the driving range improved. Furthermore, the structural battery has a capacity of approximately 20% of that of a lithium-ion battery, which is less than that of a lithium-ion battery, but the weight is significantly reduced because there is no separate battery, and as a result, the energy required to power the electric vehicle is reduced. Additionally, the structural battery has a lower electrical energy density and higher stability. Such a structured battery contains a laminated structure consisting of a negative electrode layer 510 and a positive electrode layer 520, as shown in 2 and 3 The negative electrode layer and the positive electrode layer each contain a negative electrode and a positive electrode, respectively, each provided with electrode slurry layers 512 and 522 applied to both surfaces of a carbon fiber current collector layer 530. Glass fiber insulating layers 542 and 544 are provided on an outer part of the carbon fiber current collector layer 530. A structural gap G is formed between the electrode slurry layers 512 and 522 and the glass fiber insulating layers 542 and 544 to prevent interference. The edge portions of the carbon fiber current collector layers 530 are attached to the glass fiber insulating layers 542, 544, and 546 with a resin material 535. At this point, the glass fiber insulating layers 542, 544, and 546 form layers of the same height as the negative electrode slurry layer 512, which is applied to the upper surface of the carbon fiber current collector layer 530 of the negative electrode layer 510, and the positive electrode slurry layer 522, which is applied to the upper surface of the carbon fiber current collector layer 530 of the positive electrode layer 520. Accordingly, the design gap G provides a gap between the glass fiber insulating layer 542 at the location where the resin material 535 is positioned and the corresponding negative electrode slurry layer 512, as well as between the glass fiber insulating layer 544 at the location where the resin material 535 is positioned and the corresponding positive electrode slurry layer 522, so that contamination of the slurry layers of the negative electrode layer 510 and the positive electrode layer 520 can be prevented. However, if the construction gap G is formed, there is a possibility of a short circuit between the carbon fiber collector layers during the manufacture of the structural battery due to a fine strand structure of the carbon fiber collector layer 530 and a height tolerance of the upper and lower carbon fiber collector layers 530. SUMMARY The disclosure seeks to provide a structural battery for an electric vehicle in which an electrode slurry is impregnated into the interior of a carbon fiber current collector layer in a structural battery with a series-connected structure to improve energy density, and an electrolyte layer coating extending to an outer region of the carbon fiber current collector layer to prevent interference between carbon fiber current collector layers. According to an exemplary embodiment, a structural battery for an electric vehicle is provided in which a plurality of negative electrode layers, a plurality of electrolyte layers and a plurality of positive electrode layers are successively laminated from top to bottom, wherein the negative electrode layer and the positive electrode layer each contain a negative electrode and a positive electrode, wherein an electrode slurry layer is applied to both surfaces of a carbon fiber current collector layer, and the carbon fiber current collector layer is formed by impregnating an electrode slurry formed from the electrode slurry layer into an inner porous layer