Embedded Conductive Member Battery Container Design

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Solution Overview

Problem

Existing battery configurations require thick sandwiching and collector members for strength, leading to increased cost and difficulty in reducing battery size.

Innovation Solution

A battery design featuring a battery container made of insulating material with embedded conductive members that connect cells within the container, allowing for reduced size and cost by eliminating the need for external holding members and optimizing cell arrangement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thick sandwiching members and collector portions are used to ensure high strength, then the structural strength is improved, but the battery size and cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidbattery size

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The battery container's wall portion is merged with the conductive member function, eliminating the need for separate thick sandwiching members and collector portions. The conductive member is embedded directly into the battery container wall, combining structural support and electrical connection functions into a single integrated component, thereby reducing overall battery size while maintaining necessary strength.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery container wall portion serves multiple functions simultaneously: it provides structural enclosure, acts as a conductive path for electrical connections, and embeds the conductive member for cell connectivity. This multi-functionality eliminates the need for separate dedicated strength-providing components, reducing battery size and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If thick sandwiching members and collector portions are used to ensure high strength, then the structural strength is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The battery container and conductive member are merged into a single integrated structure where the conductive member is embedded in the container wall during manufacturing. This eliminates the need for separate production and assembly of thick sandwiching members and collector portions, reducing manufacturing steps and material costs while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery container wall is designed to perform both structural and electrical conduction functions simultaneously. By making the container wall itself serve as the conductive path and embedding the conductive member directly, the design eliminates the need for separate expensive structural components, thereby reducing manufacturing cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Volume of stationary object

If the battery container is made with embedded conductive members, then the battery size is reduced, but the heat management capability may be affected

Engineering Contradiction:

Improvebattery sizeVSAvoidheat management

Core Design Contradiction:

Volume of stationary objectVSTemperature

Solution Approach 1:

The conductive member embedded in the battery container wall serves dual functions: providing electrical connection between cells and acting as a heat conduction path. This multi-functionality allows the same structure to manage both electrical connectivity and thermal management, preventing heat accumulation while maintaining reduced battery size.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The conductive member acts as an intermediary that facilitates both electrical current flow and heat transfer between adjacent cells. By embedding this conductive member in the container wall, it serves as a thermal bridge that helps dissipate heat efficiently without requiring separate dedicated cooling structures, thus maintaining compact battery size.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enables a compact and cost-effective battery configuration with enhanced connection reliability and reduced heat resistance, facilitating efficient temperature management and assembly simplicity.

Implementation Method 1

a conductive member for use in connecting the plurality of cells is embedded in a wall portion of the battery container

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a heat conducting fin extending from the conductive member into the conducting path

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10205142B2Battery, battery pack, and method of manufacturing battery

Publication Date: 2019.02.12 TOYOTA JIDOSHA KK

AI summary

A battery including a plurality of cells housed in a battery container, wherein the battery container is formed of an insulating material and includes a plurality of housing portions formed by an inner wall portion of the battery container, each of the housing portions housing an associated one of the cells, and a conductive member for use in connecting the plurality of cells is embedded in a wall portion of the battery container. The housing portion has a shape conforming to an outer face of the cell and is in contact with the outer face of the cell.