Battery Cell Tab Crimping for Modular EV Power Systems
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Solution Overview
Problem
There is a need for improved battery systems in xEVs that enhance travel distance without recharging, improve performance, and reduce costs, while also addressing packaging challenges in converting traditional vehicles to hybrid electric vehicles.
Innovation Solution
The development of lithium ion battery modules with a crimping element for secure electrical connections between tab electrodes, allowing for easy assembly and disassembly, and a DC-to-DC converter to provide multiple voltage levels within a standard lead acid battery form factor, facilitating efficient heat management through passive and active cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If traditional battery systems are used in xEVs, then vehicle power needs are met, but travel distance is limited and performance is constrained
Solution Approach 1:
The battery system is divided into multiple individual battery cells that can be independently connected through interconnect assemblies. This segmentation allows for modular expansion of capacity to extend travel distance while maintaining manageable individual cell sizes for efficient packaging in vehicle applications.
2Duration of action of moving object
If battery cell capacity is increased to extend travel distance, then duration of action improves, but packaging challenges increase
Solution Approach 1:
The battery system is divided into multiple individual battery cells that can be independently connected through interconnect assemblies. This segmentation allows for modular expansion of capacity to extend travel distance while maintaining manageable individual cell sizes for efficient packaging in vehicle applications.
Solution Approach 2:
The interconnect assembly features a crimping element with arms that nest around tab electrodes, with curved portions that facilitate removal. This nested structure allows compact arrangement of multiple cells within the battery module while maintaining accessibility for assembly and disassembly operations.
3Power
If battery cells are connected in series to increase voltage and power, then performance improves, but connection reliability becomes critical
Solution Approach 1:
The crimping element incorporates curved portions at the ends of its arms, which provide progressive engagement and distribution of compressive force around the tab electrodes. This curved geometry enhances the reliability of electrical connections by ensuring uniform contact pressure and facilitating smooth assembly and disassembly operations.
Solution Approach 2:
The crimping element is designed to apply controlled compressive force parameters to secure the tab electrodes together. By optimizing the crimping force and distribution, the system achieves reliable electrical connections that maintain performance under varying operational conditions while enabling easy assembly and disassembly.
4Adaptability or versatility
If multiple voltage levels are provided within standard form factor, then adaptability improves, but device complexity increases
Solution Approach 1:
The battery module is designed with multiple battery cells that can be connected in series to provide multiple voltage levels from a single standardized package. This multi-functional approach allows the same battery module to serve different voltage requirements (e.g., 12V and 48V systems) without requiring separate battery systems, thereby reducing overall complexity while enhancing adaptability.
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 solution enables extended travel distances, improved performance, and reduced costs by providing multiple voltage levels within a standard form factor, simplifying vehicle conversions and enhancing thermal management, thus addressing the limitations of traditional battery systems.
Implementation Method 1
The crimping element is configured to apply a compressive force to the tab electrodes
Implementation Method 2
The spring element may include a specific shape for applying the compressive force onto the tab electrodes
Data Source
AI summary
A battery module includes a power assembly including a first battery cell and a second battery cell in a stacked orientation relative to each other. The first battery cell includes a first tab electrode extending therefrom, and the second battery cell includes a second tab electrode extending therefrom. The battery module also includes an interconnect assembly configured to facilitate electrically coupling the first tab electrode with the second tab electrode with the first and second battery cells in the stacked orientation. The interconnect assembly includes a crimping element disposed over the first and second tab electrodes. The crimping element is configured to apply a compressive force to the first and second tab electrodes such that the first and second tab electrodes are secured in electrical communication via direct contact.