Cylindrical Energy Cell Terminals for Easier Welding and Cooling
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Solution Overview
Problem
Existing energy storage systems for electric vehicles and grid applications face challenges in optimizing cost, package volume, mass, performance, durability, and manufacturing efficiency at the system level, despite localized optimizations at the individual cell level.
Innovation Solution
The design of a cylindrical energy storage cell with specific configurations on its top, side, and bottom surfaces, including concentric terminals, a sleeve for electrical isolation, and optimized cooling features, facilitates improved interconnect welding, thermal management, and reduced mechanical weaknesses, enhancing system-level metrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large multiple of power is required for electric vehicles, then the battery pack must include a large, dense arrangement of individual cells, but this increases the cost and mass of the battery pack
Solution Approach 1:
The battery pack is segmented into modular units, each containing a specific arrangement of cells configured to provide predetermined voltage and current outputs. This modular approach allows systematic scaling of power while managing mass through standardized building blocks.
Solution Approach 2:
Different cell configurations are applied to different modules based on specific performance requirements. By optimizing local cell arrangements within modules rather than using a uniform dense arrangement throughout, the system achieves required power output with reduced overall mass.
2Power
If individual cells are individually placed or configured into modules to achieve power requirements, then the battery pack composition can be optimized, but this increases device complexity
Solution Approach 1:
Standardized module designs serve multiple functions: they provide electrical connections, structural support, and thermal management interfaces. This multi-functionality reduces the number of separate components needed, simplifying the overall battery pack configuration while maintaining power output requirements.
Solution Approach 2:
Multiple cell configurations and ancillary components are merged into integrated module assemblies. By combining these elements into pre-configured modules rather than arranging individual cells separately, the system achieves required power output with reduced configurational complexity.
3Power
If the battery pack is designed to meet power requirements with dense cell arrangement, then performance is improved, but manufacturing and assembly become more difficult
Solution Approach 1:
Cells are pre-configured into modules with predetermined arrangements before final battery pack assembly. This preliminary configuration of cell groups into standardized modules simplifies the final assembly process while maintaining the dense arrangement needed for high power output.
Solution Approach 2:
The manufacturing process is segmented into modular assembly steps: cell assembly into modules, module testing, and final pack integration. This segmentation of the manufacturing process makes assembly more manageable and easier to quality-control compared to assembling individual cells into a dense arrangement.
Data Source
AI summary
A system for incorporating one or more individual energy cells is provided. Individual energy cells include a top surface having a center terminal and an outer terminal. The first terminal and the second terminal are configured as substantially planar electrical contacts. The cell further includes a side surface mechanically connected to the top surface and a bottom surface mechanically connected to the side surface.