Battery Cell Interconnect Using Cell Casing for Space-Efficient Cooling
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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 an anode tab is in physical contact with another cell's cathode casing, with an insulating layer to isolate electrically, and a conductive layer enhancing conduction between cells, allowing for efficient electrical communication and improved cooling through increased surface area for heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bus bars and interconnection systems are used to connect battery cells, then electrical communication between cells is established, but space within the battery pack is consumed that could be used for other purposes
Solution Approach 1:
The patent merges the interconnection function with the battery cell structure itself by making the cathode casing conductive and using it as the interconnection element. This eliminates the need for separate bus bars and interconnection systems, thereby consuming less space within the battery pack while maintaining electrical communication between cells.
Solution Approach 2:
The cathode casing serves multiple functions: it provides structural containment for the cathode components and simultaneously acts as the electrical interconnection element (bus bar) for connecting to adjacent cells. This multi-functionality reduces the number of separate components needed, optimizing space utilization within the battery pack.
2Reliability
If conventional interconnection systems are used, then battery cells are electrically connected, but space efficiency and cooling efficiency are reduced
Solution Approach 1:
The interconnection system is merged with the cell structure by using the conductive cathode casing as the connection element, eliminating separate bus bars and improving space efficiency while maintaining electrical connection reliability.
Solution Approach 2:
The patent transitions from using separate three-dimensional bus bar components to utilizing the two-dimensional surface of the cathode casing for interconnection. This dimensional change allows for more efficient space utilization and potentially improved thermal contact area for cooling.
3Reliability
If conventional interconnection systems are used, then electrical communication is achieved, but thermal concentration increases due to reduced heat dissipation surface area
Solution Approach 1:
The interconnection system and thermal management system are merged by using the conductive cathode casing as both the electrical connection element and the heat dissipation surface. This eliminates the need for separate bus bars that would limit thermal contact area, thereby reducing thermal concentration.
Solution Approach 2:
The cathode casing serves dual purposes as both the structural container and the thermal management interface. By making it conductive, it simultaneously provides electrical interconnection and enhanced heat dissipation capability, reducing thermal concentration without requiring additional cooling components.
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 and heat dissipation, reducing thermal concentration and prolonging battery life by allowing for more efficient use of the available volume within the battery pack.
Implementation Method 1
A battery cell is configured to maintain electrical communication with other battery cells within a battery pack by being in physical contact with one or more other cells within the pack
Implementation Method 2
an insulating layer for electrically isolating the anode tab from the cathode casing
Implementation Method 3
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
Implementation Method 4
improved cooling through increased surface area for heat dissipation
Data Source
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.