Horizontal Composite Battery Structure for Safety and Capacity
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Solution Overview
Problem
Existing electric vehicle battery systems face safety concerns due to vertical stacking, which leads to high voltage drops and potential explosions upon puncture by metal objects, and are limited by the maximum voltage of the electrolyte, restricting capacity and performance.
Innovation Solution
A horizontal composite electricity supply structure is developed, featuring series and/or parallel connections between electrochemical system element groups within insulation layers, with shared current collecting layers and a package layer to prevent electrolyte circulation, enhancing safety and capacity without voltage limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple electrochemical system elements are vertically stacked to achieve high voltage and capacity, then the energy density and capacity are improved, but the safety risk increases due to puncture damage by metal objects causing voltage drop and potential explosion
Solution Approach 1:
The patent transitions from vertical stacking to horizontal arrangement of electrochemical system elements. This dimensional change eliminates the puncture risk associated with vertical stacking while maintaining high capacity through parallel connections of multiple elements in the horizontal plane.
Solution Approach 2:
The battery system is divided into multiple independent electrochemical system elements connected in parallel. Each element is encapsulated separately, and the horizontal arrangement allows current collecting layers to be shared between adjacent elements, reducing internal resistance while maintaining safety through isolation of individual elements.
2Power
If internal series connection is adopted to increase voltage within a single housing, then the voltage is improved, but the electrolyte decomposition occurs when voltage exceeds the sustainable range
Solution Approach 1:
Instead of using internal series connection that pushes voltage beyond electrolyte limits, the patent divides the system into multiple independent electrochemical elements. Each element operates within the safe voltage range of the electrolyte, while the overall system achieves higher voltage through controlled series connection of complete element groups.
Solution Approach 2:
The patent introduces current collecting layers as intermediaries between adjacent electrochemical system elements. These layers facilitate controlled electrical connection while maintaining electrolyte isolation, allowing voltage accumulation without direct series connection that would cause electrolyte decomposition.
3Quantity of substance
If external parallel connection is used to increase capacity, then the capacity is improved, but the device complexity increases due to multiple housings and external connections
Solution Approach 1:
The patent merges multiple electrochemical system elements into a single integrated housing with shared current collecting layers. The horizontal arrangement allows adjacent elements to share common current collecting layers, eliminating the need for separate external connections while achieving parallel connection for increased capacity.
Solution Approach 2:
The current collecting layers serve multiple functions: they collect current from multiple adjacent electrochemical system elements simultaneously and act as shared components between elements. This multi-functionality reduces the number of separate components needed and simplifies the overall structure.
4Use of energy by moving object
If a great number of electricity supply elements are vertically stacked to achieve high capacity and voltage, then the energy density is improved, but the harmful factors increase due to extreme danger from puncture-induced voltage drop
Solution Approach 1:
The patent arranges electrochemical system elements horizontally rather than vertically, fundamentally changing the spatial configuration. This eliminates the puncture pathway through the stacked elements while maintaining high energy density through efficient horizontal packing and shared current collecting layers.
Solution Approach 2:
The patent converts the potential harm of puncture damage into a benefit by using the horizontal arrangement to naturally prevent puncture pathways. The shared current collecting layers in the horizontal configuration create a structure where puncture cannot propagate through multiple elements as it would in vertical stacking.
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 design reduces internal resistance, increases charging and discharging speeds, simplifies cooling, and significantly enhances the reliability and safety of the battery system by preventing electrolyte decomposition and explosion risks while allowing higher voltage and capacity without electrolyte voltage limitations.
Implementation Method 1
multiple electrochemical system elements connected in series and/or in parallel
Implementation Method 2
shared current collecting layers... reduces internal resistance
Data Source
AI summary
The present disclosure relates to a horizontal composite electricity supply structure, which comprises a first insulation layer, a second insulation layer, two electrically conductive layers, and a plurality of electrochemical system element groups. The two electrically conductive layers are disposed on the first and second insulation layers, respectively. The electrochemical system element groups are disposed between the first insulation layer and the second insulation layer, and connected in series and/or in parallel via the electrically conductive layers. The electrochemical system element group is formed by several serially connected electrochemical system elements. Each electrochemical system element includes a package layer on the sidewall, so that their electrolyte systems do not circulate with one another. Thereby, the high voltage produced by connection will not influence any single electrochemical system element nor decompose their respective electrolyte systems. Hence, serial and/or parallel connections are made concurrently in the horizontal composite electricity supply structure.