Battery Planar Tab Interconnect Using Conducting Wire

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Solution Overview

Problem

Existing information handling systems face inefficiencies in power tab connections for battery cells, as traditional spot welding methods consume excessive surface area on power circuit boards, leading to space constraints and potential breakage of pliable power tabs.

Innovation Solution

A high current battery cell planar tab interconnect method using a conducting wire that is spot welded to the power tabs, rolled along them to reduce length, and then wrapped around, allowing for efficient connection to a power circuit board via smaller via pairs or power standoffs, reducing surface area consumption and enabling easy bending without breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional spot welding methods are used to connect power tabs to the power circuit board, then reliable electrical connection is achieved, but excessive surface area is consumed on the power circuit board

Engineering Contradiction:

Improveconnection reliabilityVSAvoidsurface area on power circuit board

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The connection system is divided into separate functional components: the power tab remains attached to the battery cell, while a separate conducting wire (with smaller cross-sectional area than traditional pads) carries the electrical connection to the power circuit board. This segmentation allows the bulky power tab to remain localized at the battery while using minimal board space for the actual electrical connection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A conducting wire serves as an intermediary element between the power tab and the power circuit board. This wire acts as a mediator that transfers electrical current from the battery tab to the board through smaller via pairs, eliminating the need for large surface area pads while maintaining reliable electrical connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If power tabs are made pliable to allow bending during installation, then ease of installation is improved, but the tabs become susceptible to breakage

Engineering Contradiction:

Improveease of installationVSAvoidresistance to breakage

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system separates the flexible connection function from the structural support function. The power tab maintains its structural integrity and remains relatively rigid, while a separate conducting wire provides the necessary flexibility and bending capability. This segmentation allows each component to optimize its mechanical properties without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conducting wire acts as a flexible element that can be bent and routed as needed during installation, replacing the need for flexible power tabs. This flexible wire maintains electrical connectivity while accommodating installation requirements, eliminating the breakage risk associated with bending rigid tabs.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If larger surface area is allocated for power tab connections, then connection reliability is improved, but space availability on the power circuit board is reduced

Engineering Contradiction:

Improveconnection reliabilityVSAvoidavailable space on power circuit board

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The electrical connection function is extracted from the large surface area power tab and relocated to a separate conducting wire with minimal cross-sectional area. This extraction allows the power tab to remain compact at the battery cell while the connection to the power circuit board uses minimal board space through small via pairs, maximizing available space.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The connection approach transitions from a two-dimensional surface area connection (large pads on the board) to a three-dimensional wire-based connection. The conducting wire extends vertically through via pairs, utilizing the Z-dimension (depth) rather than consuming horizontal board space, thereby maintaining reliable connection with minimal surface area usage.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 method provides a more efficient and space-saving power connection for battery cells, allowing for effective power distribution while minimizing surface area usage on the power circuit board and ensuring the pliability of power tabs, thus enhancing the reliability and efficiency of information handling systems.

Implementation Method 1

A high current battery cell planar tab interconnect method using a conducting wire that is spot welded to the power tabs

Methodology Applied

Scientific EffectSpot welding: Welding

Data Source

PatentUS11515606B2Information handling system with high current battery planar tab interconnect

Publication Date: 2022.11.29 DELL PROD LP

AI summary

A battery cell includes a first power tab and a first conducting wire. The first power tab may include a proximal end connected to the battery cell, and may provide a first output terminal for the battery cell. The first conducting wire may be connected to a distal end of the first power tab, and may be encircled by the first power tab. The first conducting wire may connect with a power circuit board to provide power from the battery cell.