Modular Lithium-Ion Battery Assembly With Flexible Current Collector
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Solution Overview
Problem
Conventional lithium-ion batteries for industrial applications are cumbersome due to multiple form factors, high complexity, and increased maintenance needs, with existing modularization methods leading to increased size, weight, and vulnerability to environmental factors, while lacking a seamless 'drop-in' replacement for lead acid batteries.
Innovation Solution
A modular lithium-ion battery architecture with a flexible current collector and integrated battery management system, allowing for easy adaptation to various voltages and capacities by changing the number of cells, reducing the need for external connectors and enhancing environmental resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple lithium-ion batteries are connected in series to build up voltage (as done with lead acid), then system voltage is achieved, but the complexity of series connections increases and additional cost is added
Solution Approach 1:
The patent combines multiple battery cells into a single integrated module with internal series connections already established. The module integrates the battery cells, current collectors, and connections into one unified structure, eliminating the need for external series connections between multiple separate batteries while achieving the desired system voltage.
Solution Approach 2:
The patent nests multiple battery cells within a single module housing, with internal current collectors and connections nested between the cells. This nested arrangement allows series connections to be made internally within the module rather than externally between separate battery units, reducing overall system complexity.
2Adaptability or versatility
If multiple external connectors and connections are used to modularize batteries, then flexibility is improved, but the space occupied increases and durability decreases
Solution Approach 1:
The patent merges the battery cells, current collectors, and electrical connections into a single integrated module. This consolidation eliminates multiple external connectors and interconnections, reducing the space required while simultaneously improving durability by removing vulnerable connection points that are exposed to environmental factors.
Solution Approach 2:
The integrated module serves multiple functions simultaneously: it provides the battery cells for energy storage, contains the current collectors for electrical conduction, and houses the internal connections for series/parallel configurations. This multi-functional design achieves flexibility without requiring separate external connectors for each function.
3Adaptability or versatility
If conventional battery architectures with multiple form factors are used, then different voltage classes are achieved, but the bill of materials increases and integration complexity increases
Solution Approach 1:
The patent segments the battery system into standardized modules that can be internally configured in different series/parallel arrangements. Each module contains multiple cells that can be connected internally to provide different voltage classes, allowing the same module design to serve multiple voltage requirements without requiring different form factors.
Solution Approach 2:
The patent achieves different voltage classes by changing the internal connection configuration parameters within the same module design. By altering how the cells are connected internally (series vs. parallel arrangements), the module can provide different voltage and capacity outputs without changing the physical form factor or requiring different components.
Data Source
AI summary
Systems and methods for a battery can comprise cells connected in parallel to form a group and groups of cells connected in series to form first and sub-assemblies with components suitable for multiple battery configurations. The first subassembly comprises a lower cell carrier and upper cell carrier between which the first groups of cells are disposed. The second subassembly comprises the lower cell carrier and upper cell carrier between which the second groups of cells are disposed. The flexible current collector comprises two or more conductive regions. The first and second subassemblies are connected in parallel or series to build the desired voltage or capacity of the battery. The flexible current collector is folded around the first and second subassemblies and disposed within casing to provide environmental protection to the battery, and positive and negative terminals connected to first and second conductive regions, respectively, to form positive and negative terminals of the battery.