Battery Cell Electrode Interconnection Using Inclined Flag Stacking
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Solution Overview
Problem
Conventional electrical energy storage systems, such as batteries and power capacitors, require significant space due to the parallel arrangement of flags and external terminals, which limits volumetric efficiency and increases material costs.
Innovation Solution
The proposed solution involves a space-saving configuration where the majority of flags in a flag stack are bonded to the external terminal at an inclined angle, with non-terminal-adjacent flags being shorter and oriented more obliquely, allowing for a compact interconnection arrangement that reduces the structural space required for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If flags are arranged in a conventional parallel configuration for bonding to external terminals, then electrical connection reliability is maintained, but the volume occupied by interconnection components increases and volumetric efficiency decreases
Solution Approach 1:
The patent transitions from a two-dimensional parallel arrangement of flags to a three-dimensional stacked configuration where flags are bonded in layers. Multiple flags are stacked vertically and bonded to the external terminal in a compact stack, utilizing the third dimension (height/depth) to reduce the footprint area while maintaining all necessary electrical connections.
Solution Approach 2:
The patent implements a nested structure where multiple flags are stacked one on top of another, with each flag nested within the bonding space of the previous flag. This nested arrangement allows multiple electrical connections to be packed into a compact volume, significantly reducing the space required for interconnection components while maintaining reliability through proper bonding of each flag in the stack.
2Ease of manufacture
If more space is allocated for flag bonding arrangements, then manufacturing and assembly simplicity is maintained, but volumetric efficiency of the energy store decreases
Solution Approach 1:
The patent merges multiple flag bonding operations into a single integrated stack structure. Instead of bonding each flag separately to the external terminal in a sequential planar arrangement, multiple flags are stacked and bonded together in one consolidated bonding process, simplifying manufacturing while achieving compact volumetric efficiency.
3Area of stationary object
If flags are arranged with larger spacing for conventional bonding, then bonding process simplicity is maintained, but the space required for electrical connections increases
Solution Approach 1:
The patent resolves the spacing issue by moving the bonding arrangement from a two-dimensional plane to a three-dimensional stack. Flags are spaced closely in the planar view but are separated vertically in the stack, allowing compact packaging without requiring large lateral spacing. This dimensional transition enables dense packing while maintaining bonding simplicity through the stacked configuration.
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 significantly reduces the space needed for electrical connections, enhancing volumetric efficiency and reducing material usage, while maintaining mechanical stability and low electrical resistance, thus improving the power-weight ratio and lowering production costs.
Implementation Method 1
A plurality of flags are arranged one on top of another in a flag stack, and are respectively materially bonded, both mutually and with an associated external terminal
Data Source
AI summary
An electrical energy store having a spatially-optimized electrode interconnection. The electrical energy store (1) comprises flat electrodes (3), flags (7) projecting laterally from the electrodes (3), and external terminals (9). A plurality of electrode regions are respectively stacked, one on top of another, to form an electrode stack (14). A plurality of flags (7) are arranged one on top of another in a flag stack (15), and are respectively materially bonded, both mutually and with an associated external terminal (9). The energy store is characterized in that each flag (7) of a plurality of flags (7) in a flag stack (15), which is bonded to the associated external terminal (9), is materially bonded to a respectively adjoining flag (7) in a region in which the flag (7) is oriented in an inclined direction at an angle (α) to the surface (11) of the associated external terminal (9).