Multi-Layer Current Collector Assembly for Stable Battery Output
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery systems face challenges in efficiently collecting and distributing electrical charge from multiple battery cells, particularly in high-power applications such as electric vehicles, where current collectors often fail to provide reliable and efficient voltage output due to issues like electrical interference and mechanical stress.
Innovation Solution
A multi-layer current collector assembly is introduced, comprising two conductive layers with tabs and an insulating layer in between, designed to vertically stack and connect to battery cells, enhancing electrical conductivity and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-layer current collector is used, then the structure is simple, but the charge collection efficiency and mechanical robustness are insufficient for high-power applications
Solution Approach 1:
The current collector is divided into multiple conductive layers (first conductive layer and second conductive layer) stacked vertically, with each layer containing tabs for collecting electrical charge from different battery cells. This segmentation allows parallel charge collection paths, improving overall charge collection efficiency while distributing mechanical stress across layers
Solution Approach 2:
The invention transitions from a single-plane (2D) current collector structure to a multi-layer stacked (3D) structure by adding the vertical dimension. The first and second conductive layers are positioned at different heights with an insulating layer between them, creating a three-dimensional arrangement that enhances charge collection capability without requiring a larger footprint area
2Volume of moving object
If conductive layers are placed close together to reduce size, then the assembly is compact, but electrical interference between layers occurs
Solution Approach 1:
An insulating layer is introduced as an intermediary element positioned between the first conductive layer and the second conductive layer. This insulating layer electrically isolates the two conductive layers, preventing electrical interference and short circuits while allowing the layers to remain in close proximity for a compact assembly design
Solution Approach 2:
The insulating layer serves multiple functions simultaneously: it provides electrical insulation between conductive layers, maintains structural spacing to prevent short circuits, and contributes to the overall mechanical stability of the stacked assembly. This multi-functionality allows compact design without compromising electrical performance
3Power
If multiple battery cells are connected in parallel to increase power output, then the power capacity increases, but the mechanical stress and electrical interference increase
Solution Approach 1:
Multiple battery cells are distributed across different conductive layers, with each layer handling a subset of connections. This segmentation of connections across layers distributes mechanical stress more evenly and reduces electrical interference by separating current paths vertically, while still achieving high power output through parallel configuration
Solution Approach 2:
The invention uses the vertical stacking dimension to organize multiple battery cell connections, moving from a planar arrangement to a three-dimensional stacked arrangement. This vertical distribution of tabs and connection points across multiple layers reduces mechanical stress concentration and minimizes electrical interference while maintaining high power capacity
Data Source
AI summary
A current collector assembly for battery systems may include a first conductive layer with a first plurality of tabs and a second conductive layer with a second plurality of tabs, both configured to connect to battery cells in a row. An insulating layer may separate the conductive layers, which may be vertically stacked with staggered tabs. The assembly may include elongated bars or repeating conductive islands to enhance scalability and efficiency. Integrated into a battery subassembly, it supports series and parallel connections to optimize voltage and energy capacity. The design may affect electrical performance, thermal management, or high-density battery pack configurations.