Collector Plate Battery Module Assembly for Small Cell Integration
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Solution Overview
Problem
Current battery systems face increased complexity and cost due to the integration of multiple components and redundant functionalities when using small format battery cells, which complicates the manufacturing process and requires significant resources for assembly.
Innovation Solution
The use of collector plates with overhangs and dielectric layers to simplify the connection of multiple small format battery cells into larger modules, reducing redundant components and assembly time, while maintaining high precision and cost-effectiveness by integrating safety features like fuses and sense circuits directly into the collector plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If small format battery cells are used to increase manufacturing yield and safety, then manufacturing yield and safety are improved, but device complexity increases due to positioning and current conveyance requirements
Solution Approach 1:
The patent combines multiple small format battery cells into a single integrated battery module with a unified current collector structure. This merging approach maintains the safety and manufacturing yield benefits of small cells while reducing the complexity of positioning and current conveyance by treating the assembly as a single unit rather than multiple discrete cells requiring individual connections.
Solution Approach 2:
The battery module design incorporates a universal current collector structure that can accommodate multiple small format cells simultaneously. This multi-functional current collector serves both as an electrical connection element and as a structural framework for cell positioning, thereby reducing the number of separate components needed and simplifying the manufacturing process.
2Quantity of substance
If small format battery cells are used to enable higher energy density chemistries, then energy density is improved, but device complexity increases due to the need for multiple electrical interconnects
Solution Approach 1:
The patent merges multiple small format battery cells into a single module with a unified current collector that consolidates multiple electrical interconnect functions. This approach maintains the high energy density enabled by small cells while reducing the complexity of electrical connections by using a single integrated current collector structure instead of multiple separate interconnects.
3Quantity of substance
If multiple small format battery cells are aggregated into a battery system, then energy storage capacity is improved, but manufacturing cost increases due to combination time and resource requirements
Solution Approach 1:
The patent employs preliminary action by pre-assembling multiple small format battery cells into integrated modules with built-in current collectors before final system assembly. This preliminary integration of cells and current collectors reduces the time and resources required during final manufacturing assembly, thereby lowering overall manufacturing costs while maintaining high energy storage capacity.
Solution Approach 2:
The patent combines multiple small format battery cells into integrated modules with unified current collector structures. This merging reduces the number of separate assembly operations and resource requirements needed to combine individual cells into a complete battery system, thereby reducing manufacturing cost per unit of energy storage capacity.
Data Source
AI summary
A battery system includes multiple cells arranged in a common cell enclosure that can also be used for a structure and heat transfer fluid conduit. The battery system also includes a first collector plate. The first collector plate has multiple collector tabs that correspond to the multiple cells. Each collector tab is connected to a cathode of a corresponding cell from amongst the multiple cells present in the battery system.