Annular Battery Cell Connector Layout for Compact HV Pack Wiring
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Solution Overview
Problem
Conventional multi-cell high-voltage storage devices with round cells require extensive and complex cell connectors for series and parallel connections, leading to high material usage, weight, and production complexity, which complicates accessibility and scalability.
Innovation Solution
A cell connector arrangement where series and parallel connectors are spaced apart on the annular pole of cylindrical battery cells, utilizing the annular pole as a connection conductor to reduce connector size and complexity, enabling smaller, more flexible, and identical connectors for various interconnection patterns across different cell geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extensive cell connectors are used for series and parallel connections of round battery cells, then reliable electrical connections are achieved, but material usage increases, weight increases, and production complexity increases
Solution Approach 1:
The cell connector is divided into multiple connector elements that are distributed around the circumference of the annular pole. Instead of using one extensive connector, multiple smaller connectors are spaced apart, each establishing electrical connections to adjacent battery cells. This segmentation reduces the amount of connector material needed while maintaining reliable electrical connections across all series and parallel connections.
Solution Approach 2:
The annular pole serves multiple functions: it acts as the electrical terminal for the battery cell and simultaneously serves as a mounting structure for multiple connector elements. The annular pole's cylindrical geometry allows connectors to be arranged in various patterns (e.g., alternating series and parallel connectors), enabling a single component design to handle multiple connection configurations without requiring different extensive connector structures.
2Reliability
If extensive cell connectors are used to cover large regions of the cell surface, then all series and parallel connections are achieved, but production complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The connector system is segmented into multiple identical or standardized connector elements that can be manufactured using the same process. Each connector element is a discrete, manageable component rather than one large complex structure. This standardization of connector elements simplifies manufacturing, quality control, and assembly, while the distributed arrangement ensures comprehensive electrical connection coverage.
Solution Approach 2:
Connector elements are placed at specific locations around the annular pole where they are most needed for electrical connections. The spacing and distribution of connectors are optimized locally to achieve proper electrical connectivity without requiring uniform extensive coverage. This allows production to focus on placing connectors at critical positions rather than manufacturing large continuous connector structures.
3Power
If extensive cell connectors are used for high line cross sections, then adequate current carrying capacity is achieved, but connector width increases and accessibility of round cells is reduced
Solution Approach 1:
The current carrying function is distributed across multiple connector elements spaced around the annular pole rather than concentrated in one wide connector. Each connector element carries a portion of the total current, and their combined cross-sectional area provides adequate overall current carrying capacity. This segmented approach allows round cells to remain accessible for adhesively-bonding and casting operations while still achieving the required electrical power transmission capability.
4Reliability
If one or a few extensive cell connectors are used for a large number of round cells, then connection coverage is achieved, but connector complexity and material use increase
Solution Approach 1:
The connection coverage function is achieved by distributing multiple simple connector elements around the annular pole rather than using one or a few complex extensive connectors. Each connector element is relatively simple in design, and their collective arrangement provides comprehensive coverage for connecting to multiple round cells in series and parallel configurations. This reduces both the complexity of individual connectors and the overall system complexity.
Solution Approach 2:
Instead of changing the scale and complexity of connectors to accommodate more cells, the solution changes the number and distribution of connectors. Multiple connectors with moderate parameters are used instead of fewer connectors with extreme parameters (large size, high complexity). This parameter transformation allows the system to scale to accommodate a large number of round cells while maintaining manageable connector complexity.
Data Source
AI summary
The present subject matter relates to a cell connector assembly for a battery cell of an assembly of battery cells. A serial connector electrically connects a circular annular ring pole of the battery cell to an inner pole of the opposite polarity of at least one other battery cell of the assembly. A parallel connector connects the ring pole to a ring pole of the same polarity of at least one respective other battery cell. The serial connector and the parallel connector and/or at least two parallel connectors are mutually spaced on the ring pole in the circumferential direction. A multi-cell high-voltage storage device includes multiple battery cells, each of which has an inner pole and a circular annular ring pole arranged radially about the inner pole. A cell connector set comprises multiple cell connectors configured to connect the battery cells of the high-voltage storage device together.