Electrochemical grid and segmented cell architecture for modular high-current battery modules

Abstract

Electrochemical cell with a modular, segmented architecture, comprising at least one central anode structure, a cathodic element designed as an outer casing, segmented insulating layers between the electrodes, and a grid structure arranged between the casing and the anodes, wherein the grid structure is designed to control the local ion flow, homogenize the current density distribution, and reduce thermal peaks, and wherein each electrode pair forms an electrochemical segment that can be independently activated and monitored.

Description

Technical field

[0001] The invention relates to electrochemical energy storage devices, in particular lithium-ion cells and battery modules built therefrom for applications with high current requirements. The invention relates to both an electrochemical grid structure for controlling the ion flow and a segmented cell architecture that enables modular activation of individual electrode regions.

[0002] Furthermore, the invention relates to standardized block cells that integrate several electrochemical segments within a common cathodic housing. State of the art

[0003] Conventional lithium-ion cells exhibit inhomogeneous ion fluxes, increased local reaction rates, and pronounced temperature gradients at high charge and discharge rates. These effects lead to accelerated aging, capacity loss, and thermal stress.

[0004] Known solutions focus predominantly on external thermal measures, without structurally influencing the internal ion flow distribution or the electrochemical segmentation of the cell.

[0005] A combination of electrochemical grid structure, segmented cell architecture and a standardized multi-segment block is not known in the prior art. Object of the invention

[0006] The invention aims to: 1. to provide an electrochemical lattice structure that homogenizes the local ion flow within the cell, 2. To reduce thermal gradients and local overloads, 3. to enable a segmented cell architecture in which multiple electrode pairs can be operated independently of each other, 4. to provide a modular battery module made up of several segmented cells, 5. and to create a standardized multi-segment block (e.g. 6 V) that integrates several electrochemical segments within a common cathodic housing. Description of the invention: 1. Electrochemical grid

[0007] The invention comprises a grid (4) arranged between the electrode coating and the separator or formed integrally on a current collector (5).

[0008] The grid has defined geometric parameters such as step size p, thickness t, web width w and openness φ.

[0009] The structure locally influences the effective ion path, thereby smoothing the current density distribution and reducing the thermal load.

[0010] The grid structure acts as a functional current and heat distributor and stabilizes operation at high current densities. 2. Segmented cell architecture

[0011] The cell comprises a cathodic housing (1) and several anodes (3) arranged inside the housing.

[0012] Between the anodes and the housing are segmented insulating layers (2) and associated grid structures (4) that enable thermal and electrochemical decoupling of the sub-segments.

[0013] Each anode-grid-case pair forms an independent electrochemical segment that can be activated, monitored, or interconnected independently. 3. Combination of grid and segmentation

[0014] The grid structure can be assigned to each segment individually or can have a cross-segment effect.

[0015] The combination of grid and segmentation allows for a more homogeneous loading of the segments, improved heat dissipation and increased stability at high currents.

[0016] The segmented architecture reduces local hot spots and extends the cell's lifespan. 4. Modular battery module

[0017] Several segmented cells can be electrically connected in series or parallel to form modular high-current battery modules (e.g. 18 V, 36 V).

[0018] The segmented architecture allows for a more even load distribution across the cells within the module and improves the thermal stability of the overall system. 5. Standardized multi-segment block (6 V block)

[0019] In a preferred embodiment, the invention comprises a standardized multi-segment block in which several electrochemical segments within a common cathodic housing are electrically connected in series to provide a defined block voltage, in particular 6 V.

[0020] Each segment comprises its own anode structure and an intermediate grid structure, resulting in a uniform ion flow distribution and increased current carrying capacity.

[0021] The 6V block can be used as a standalone cell or as a component for larger battery systems. Design versions: Design form A - Grid as intermediate layer

[0022] The grid is arranged as a thin structure between the electrode coating and the separator. Design B - Integral on current collector

[0023] The grid is formed directly on the current collector and co-calendered with the active layer. Design C - Segmented cell

[0024] The cell comprises several anode segments arranged in a ring, radial or block shape. Design D - Modular Block

[0025] Several segmented cells are combined to form a standardized high-current module. Type E - Standardized 6V block

[0026] Several electrochemical segments within a common housing are connected in series to provide a defined block voltage of 6 V. Advantages of the invention • Homogenization of the ion flow • Reduction of local temperature peaks • Increased service life and cycle stability • Thermal and electrochemical decoupling of the segments • Compatibility with existing manufacturing processes • Scalability for modular battery systems • Possibility of standardized block voltages (e.g. 6 V) scope

[0027] The invention is suitable for high-current applications such as power tools, portable machines, industrial equipment and modular high-voltage battery systems.

[0028] With the rapid growth of electromobility, the thermal and electrochemical stability of battery cells is becoming increasingly important. The combination of segmented cell architecture and grid structures described in the invention can contribute to a more uniform ion flow distribution, thereby slowing cell aging and extending its service life. At the same time, the more homogeneous current density enables more efficient heat dissipation, which benefits both higher charging capacities and reduced temperature peaks. Legal notice

[0029] The scope of protection is determined by the claims. The description serves to interpret the claims. Reference symbol list - (Fig. 4) 1 Anode(+) central electrode structure 2 Horizontal Grids 3 Vertical Grids 4 Cathode (-) outer casing

Claims

[1] Electrochemical cell with a modular, segmented architecture, comprising at least one central anode structure, a cathodic element designed as an outer casing, segmented insulating layers between the electrodes and a grid structure arranged between the casing and the anodes, wherein the grid structure is designed to control the local ion flow, homogenize the current density distribution and reduce thermal peaks, and wherein each electrode pair forms an electrochemical segment that can be independently activated and monitored. [2] Cell according to claim 1, characterized by that two or more spatially separated anodic segments are arranged within the cathodic housing, wherein each anode segment is coupled to the housing via its own intermediate grid structure and the grid structures enable independent control of the local ion flow. [3] Cell according to claim 1 or 2, characterized by , that the anodes are designed either as vertically arranged rods, as planar segments or as ring-shaped distributed internal structures, wherein the grid structures arranged between the anodes and the housing are each adapted to the geometric shape of the anodes and effect a segmented thermal and electrochemical decoupling. [4] Cell according to any one of the preceding claims, characterized by that it includes an internal or external display or readout system which signals the activation state of individual anode segments or segment groups, whereby the display can be electrical, optical or digital. [5] Cell according to any one of the preceding claims, characterized by, that the anode segments arranged within the cathodic housing can be electrically connected either in series to increase the output voltage or in parallel to reduce the internal resistance, with the connection being carried out segment by segment and stabilized by the grid structures. [6] Cell according to claim 5, characterized by , that the switching between serial and parallel connection of the anode segments is software-controlled and dynamically adjusted based on temperature data, load profiles or external control commands. [7] Cell according to any one of the preceding claims, characterized by , that several electrochemical segments within a common cathodic housing are electrically connected in series to provide a standardized block voltage of 6 V, with each segment having its own anode structure and an intermediate grid structure to control the local ion flow.

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