Battery Strap Configuration for Reduced Weight and Resistance
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Solution Overview
Problem
Conventional batteries with multiple coiled cell elements require substantial additional material and weight for internal series connections, leading to increased costs and reduced performance due to longer electrical paths and higher resistance.
Innovation Solution
A battery configuration featuring six cells arranged in a 2x3 pattern with five straps, where no more than two straps cross a dividing line, providing a more efficient electrical path and reduced material usage by directly and diagonally coupling cells in series.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional batteries use multiple coiled cell elements connected in series by conductive straps, then the battery can provide sufficient power, but the material costs and weight increase substantially
Solution Approach 1:
The patent merges adjacent cell elements by removing separators between them, allowing direct electrical contact between cells. This eliminates the need for separate conductive straps to connect cells in series, thereby reducing material usage and weight while maintaining the required power output through direct cell-to-cell electrical coupling.
Solution Approach 2:
The patent extracts and removes the separators that traditionally divide cell elements in conventional batteries. By taking out these non-conductive separators, the design enables direct electrical contact between adjacent cells, eliminating the need for additional conductive straps and reducing overall battery weight and material costs.
2Reliability
If conventional batteries use conductive straps to connect cells in series, then electrical connections are established, but the electrical path length increases and resistance increases
Solution Approach 1:
The patent extracts and removes the separators between cell elements, creating direct electrical contact pathways. This elimination of intermediate non-conductive materials shortens the electrical path length and reduces the number of connection interfaces, thereby lowering electrical resistance and energy loss while maintaining reliable electrical connections.
Solution Approach 2:
The patent transitions from a conventional series connection topology using discrete straps to a direct adjacent-cell contact topology. By changing the dimensional arrangement where cells directly touch each other without intermediate connectors, the electrical path becomes more direct and shorter, reducing resistance and improving connection reliability.
3Reliability
If conventional batteries use substantial material for internal series connections, then cells can be connected in series, but the manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the need for separate conductive straps and separators by allowing direct cell-to-cell contact. This reduction in component count simplifies the manufacturing process, reduces material procurement costs, and lowers assembly complexity while maintaining reliable series connections through direct electrical contact between adjacent cells.
Solution Approach 2:
The patent merges the functions of separators and conductive straps by eliminating both components and allowing direct cell contact. This consolidation of functions into a single direct-contact architecture reduces the number of manufacturing steps, reduces material costs, and simplifies quality control while ensuring reliable electrical connections.
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 reduces material usage by 13% and improves performance by 25% in cold crank amps compared to conventional designs, while minimizing weight and electrical resistance.
Implementation Method 1
the cells are electrically coupled in series by five straps
Data Source
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Figure 3
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AI summary
The present disclosure relates to a battery for use in various applications including starting, lighting, and ignition and other purposes in vehicles such as automobiles and boats. The disclosed battery design includes a number of battery cell elements connected in series by a number of straps. The present disclosure describes a system of connecting the cells that minimizes the size and weight of the straps and increases the operating efficiency of the battery.