Integrated Cell Conductors for Space-Saving Battery Interconnects
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Solution Overview
Problem
Conventional battery cell interconnects, such as wires and busbars, occupy significant space in battery packs, reducing volumetric energy density and are susceptible to interference, especially in high-vibration or hard-to-reach locations.
Innovation Solution
The integration of conductive materials on the cell walls, with trace patterns and extensions, allows for direct electrical coupling of terminals, reducing the need for external wires and enhancing robustness, while also enabling voltage sensing, temperature measurement, and cell balancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wires and busbars are used for cell interconnects, then electrical connections can be established between cells, but significant space is occupied reducing volumetric energy density
Solution Approach 1:
The patent merges the interconnect function with the cell housing structure by integrating conductive material directly into the housing walls. The housing serves dual purposes: structural containment and electrical conduction, eliminating the need for separate wires and busbars while maintaining reliable electrical connections between cells.
Solution Approach 2:
The cell housing is designed to perform multiple functions simultaneously: it provides structural support, contains the cell components, and acts as an electrical interconnect through integrated conductive material. This multi-functionality reduces the overall number of components and minimizes space occupation.
2Reliability
If conventional wires and busbars are used for cell interconnects, then electrical connections can be established, but the system becomes susceptible to interference in high-vibration or hard-to-reach locations
Solution Approach 1:
By integrating the conductive material directly into the housing structure, the patent eliminates flexible wires that are susceptible to vibration and interference. The rigid integrated connection provides stable electrical contact that is immune to the harmful effects of vibration and difficult-to-reach locations.
3Volume of stationary object
If conductive material is integrated on cell walls to minimize space usage, then volumetric energy density improves, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes the housing wall itself as the substrate for the conductive material, changing the parameter of where the conductive material is located from a separate component to an integrated layer on the existing structure. This approach minimizes space while the trace pattern design allows for controlled manufacturing complexity.
4Reliability
If trace patterns are used to optimize contact area and heat dissipation, then electrical performance improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies different trace patterns in different locations on the housing wall to optimize local electrical performance and heat dissipation. The trace density and configuration are varied according to the specific functional requirements of each region, allowing for optimized performance while managing manufacturing precision requirements through targeted design.
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 solution minimizes space usage, reduces interference susceptibility, and improves connection reliability, enhancing the volumetric energy density and safety of battery packs by integrating conductive materials for efficient electrical connections and monitoring within the cell structure.
Implementation Method 1
a conductive material disposed on at least one large wall surface of the cell and dimensioned to cover or substantially cover a whole area of the cell at the at least one large wall surface. The conductive material further includes a first extension at the first end of the cell that is electrically coupled to the first terminal and a second extension at the second end of the cell that is affixed to the second cap plate
Implementation Method 2
The trace pattern configured to optimize a net effective contact area and a uniform heat dissipation of the trace pattern
Data Source
AI summary
A cell including a housing, a first terminal with a first polarity, a second terminal with a second polarity different from the first polarity, the second terminal being disposed on a second cap plate or on the same first cap plate in a case where the cell has one cap plate. A conductive material is disposed on at least one large wall surface of the cell and dimensioned to cover an area of the cell at the at least one large wall surface. The conductive material further includes a first extension that is electrically coupled to the first terminal, and a second extension that is affixed to the second cap plate or to the same first cap plate.