Integrated Cell Interface Block for Battery Formation
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Solution Overview
Problem
Conventional rechargeable battery cell formation systems are inefficient in terms of space and energy, with large footprints, costly power electronics, complex clamping fixtures, excessive cabling, and inadequate heat management, leading to variations in cell performance and increased manufacturing costs.
Innovation Solution
A compact system with integrated electrical circuit and contact modules, hybrid cooling using air and liquid, and intelligent charge/discharge cycle management, which reduces energy consumption and thermal gradients, enabling scalable and automated high-volume manufacturing with reduced infrastructure costs and improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional formation systems use separate power supply modules and extensive cabling to charge battery cells, then electrical connectivity and control are achieved, but system footprint and device complexity increase significantly
Solution Approach 1:
The patent combines the power supply module, contact module, and control circuitry into an integrated cell interface block. The circuit module is positioned adjacent to the cell contact module, eliminating the need for extensive external cabling and reducing system footprint while maintaining reliable electrical connectivity through integrated connections.
Solution Approach 2:
The cell interface block serves multiple functions simultaneously: it provides power supply, electrical contact, signal routing, and control operations. This multi-functional integration reduces the number of separate components needed, thereby decreasing device complexity and space requirements while ensuring reliable electrical connectivity.
2Device complexity
If conventional systems use air cooling for heat dissipation, then system simplicity is maintained, but thermal gradients increase and heat management becomes inadequate
Solution Approach 1:
The patent implements a hybrid cooling system that combines liquid cooling channels integrated into the cell interface block with air cooling. The liquid cooling circuit removes heat more effectively at the source, reducing thermal gradients, while air cooling provides additional heat dissipation capacity without significantly increasing system complexity.
3Measurement precision
If formation systems process cells individually with dedicated power modules, then measurement precision and control are improved, but energy consumption and operational costs increase
Solution Approach 1:
The patent implements energy recovery where cells in discharge mode provide power to cells in charge mode through the integrated circuit module. This self-service energy exchange reduces external power requirements and operational costs while maintaining precise measurement and control capabilities through the integrated sensing and control circuitry.
4Reliability
If extensive cabling is used to connect power supply modules to battery cells, then electrical connectivity is ensured, but heat generation increases and heat management becomes more difficult
Solution Approach 1:
The patent integrates the power supply circuitry directly into the cell interface block positioned adjacent to the cell contact module. This eliminates extensive external cabling, thereby ensuring reliable electrical connectivity through integrated connections while minimizing heat generation by removing resistive losses from long cable runs.
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
The system achieves significant space savings, improved energy efficiency, reduced thermal gradients, and enhanced automation, resulting in lower operational and capital expenditures while ensuring consistent cell performance and safety.
Implementation Method 1
a heat pipe attached to the circuit module coupled a cold plate
Implementation Method 2
cold plate, which is attached to a liquid cooling system
Data Source
AI summary
One embodiment can provide a system for conditioning rechargeable battery cells. The system can include a cell-group conditioning module. The cell-group conditioning module can include a cell interface block that includes a cell contact module and a circuit module. The circuit module can be configured to supply power to cells and can be positioned adjacent to the cell contact module. The cell-group conditioning module can further include a cell platform configured to accommodate a number of cells and an actuation mechanism coupled to the cell interface block or the cell platform and configured to reduce a distance between the cell interface block and cell platform, thereby allowing the cell contact module to establish electrical contact with the cells.