Lithium-Ion Battery Pack with 3D Stacked Cells and Single Control Circuit
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Solution Overview
Problem
Existing battery systems face challenges in providing increased energy capacity in smaller sizes, reliability in extreme temperatures, and simplicity in design and maintenance, particularly in military applications, where compactness, durability, and ease of use are crucial.
Innovation Solution
The design involves a battery pack with a plurality of lithium-ion cells arranged in a specific internal configuration within a standardized housing, coupled with a control circuit that manages cell balancing, voltage regulation, and thermal management, allowing for increased energy storage without enlarging the pack size and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of battery cells is increased to provide higher energy capacity, then the energy capacity is improved, but the battery pack size increases
Solution Approach 1:
The patent transitions from traditional linear arrangement of battery cells to a three-dimensional stacked configuration. Multiple layers of cells are arranged vertically within the housing, utilizing spatial volume more efficiently. This dimensional change allows fitting more cells (21 cells providing 16.7% higher capacity) into the same footprint, resolving the contradiction between energy capacity and pack size.
Solution Approach 2:
The patent implements a nested arrangement where battery cells are stacked within layers, and multiple layers are nested within the housing structure. The cells are organized in a compact hierarchical configuration that maximizes space utilization, allowing higher cell density without proportionally increasing the external dimensions of the battery pack.
2Volume of moving object
If the battery pack is made more compact to reduce size, then the volume is reduced, but thermal management becomes more difficult
Solution Approach 1:
The patent divides the battery pack into multiple layers with thermal management components integrated between layers. Thermal pads are positioned between adjacent battery cell layers to conduct heat away from the cells. This segmented approach to thermal management allows effective heat dissipation in the compact three-dimensional configuration, preventing thermal stress accumulation despite the reduced overall volume.
3Quantity of substance
If a non-multiple of eight cells is used to increase capacity, then the energy capacity is improved, but the control circuit complexity increases
Solution Approach 1:
The patent employs a single multi-functional control circuit that manages all 21 battery cells regardless of their non-traditional quantity. The control circuit performs cell balancing, voltage monitoring, and thermal management functions for the entire pack. This universal approach eliminates the need for multiple separate control circuits that would be required in traditional configurations, keeping the control system simple despite the unconventional cell count that enables 16.7% higher capacity.
Data Source
AI summary
The present disclosure provides an improved high watt-hour lithium ion rechargeable battery pack including a plurality of cells not comprising a multiple of eight and an electrical circuit to provide a battery pack that mimics eight cells in series. In particular, the present disclosure relates to a battery pack comprising a non-multiple of eight cells of the type typically used in a 2590 battery pack and a corresponding mechanical packing assembly. The improved electromechanical design may provide an increased capacity and reduced heat of the cells upon discharge as compared to a standard 2590 battery pack, and may also avoid an imbalance that may arise when using multiple internal battery packs. The disclosed improved battery packs require only one control circuit to provide voltage regulation as well as the protection, balancing, and fuel gauge circuit functions for all of the energy cells, leading to reductions in both complexity and cost.