Battery Cell Interconnect Using Can-to-Tab Contact and Compression

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Solution Overview

Problem

Existing battery packs face inefficiencies due to the space consumed by bus bars and interconnection systems, which could be optimized for better electrical communication and cooling within the limited volume of battery packs.

Innovation Solution

A battery cell configuration where cells are in physical contact with each other, using an anode tab and cathode casing for electrical communication, with an insulating layer to isolate the anode tab from the cathode casing, and a conductive layer to enhance conduction, allowing for efficient heat dissipation and compression to maintain reliable connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bus bars and separate interconnection systems are used to connect battery cells, then reliable electrical connection is achieved, but significant space within the battery pack is consumed

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidbattery pack volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent merges the interconnection function into the battery cell structure itself by making the cathode casing conductive and using it as the electrical connection element. This eliminates the need for separate bus bars and interconnection systems, thereby reducing space consumption while maintaining reliable electrical connection between cells through direct contact with adjacent cell casings.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cathode casing serves multiple functions: it provides structural containment for the cathode components and simultaneously acts as the electrical conductor for intercell connections. This multi-functionality eliminates the need for dedicated interconnection components, optimizing space utilization within the battery pack.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Volume of moving object

If battery cells are placed in close physical contact to maximize space utilization, then volume efficiency is improved, but thermal concentration increases

Engineering Contradiction:

Improvebattery pack volumeVSAvoidthermal concentration

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The patent introduces a phase change material as an intermediary substance between adjacent battery cells. This material absorbs excess heat through phase transition when cells are in close contact, thereby managing thermal concentration while allowing maximum space utilization through tight cell packing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If anode tab and cathode casing are in direct contact for electrical conduction, then electrical conductivity is enhanced, but short circuit risk increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidshort circuit risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies different material properties to different regions: the cathode casing is made conductive for electrical connection, while the anode tab is covered with insulating material at the contact region. This localized differentiation of material properties enables electrical conduction through the cathode casing while preventing short circuits by insulating the anode tab contact surfaces.

Inventive Principle:

Principle #3Local quality

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 configuration enhances electrical conductivity, reduces thermal concentration, and prolongs the operational life of battery cells by allowing for more efficient cooling and improved mechanical strength within the battery pack.

Implementation Method 1

an insulating layer for electrically isolating the anode tab from the cathode casing

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Implementation Method 2

a conduction enhancement layer may be applied between the anode tab of a first cell and the cathode casing of a second cell within the battery pack

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

A plurality of such battery cells may be arranged within a battery pack in contact with each other, and may be held in compression

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 4

One or more heat dissipation elements may be arranged within the battery pack, in contact with the battery cells

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS11837707B2Battery cell interconnect and methods of manufacture thereof

Publication Date: 2023.12.05 APPLE INC

AI summary

A battery cell includes a cathode casing forming all or a majority of the external can of the battery cell. The battery further includes an anode tab covering at least a portion of a face of the battery cell and an insulating layer for electrically isolating the anode tab from the cathode casing. A plurality of such battery cells may be arranged within a battery pack in contact with each other, and may be held in compression. A conduction enhancement layer may be applied between the anode tab of a first cell and the cathode casing of a second cell within the battery pack. One or more heat dissipation elements may be arranged within the battery pack, in contact with the battery cells.