Nested Battery Module Design for High Density and Flexible Voltage
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Solution Overview
Problem
Conventional battery modules are inflexible, providing only a single voltage, have suboptimal package density, inadequate heat removal, and difficulty in coupling multiple modules together, leading to increased size and inefficiencies.
Innovation Solution
A flexible, multi-voltage battery module design featuring nested cylindrical lithium ion cells with interlocking casings and bi-metallic buss bars for efficient electrical connections, integrated heat sinks for cooling, and a compact fuse configuration for safety, allowing for different voltage configurations and improved packaging density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional battery modules use a matrix configuration with spaces between cells, then manufacturing is simplified, but package density is suboptimal
Solution Approach 1:
The patent applies nesting by placing cylindrical battery cells in a hexagonal close-packed arrangement where cells are nested together such that adjacent cell centers form equilateral triangles. This nested configuration eliminates the spaces between cells found in conventional matrix arrangements, maximizing the use of available volume and achieving optimal package density while remaining manufacturable.
2Device complexity
If conventional battery modules use fixed single-voltage configuration, then device complexity is reduced, but adaptability is limited
Solution Approach 1:
The patent segments the battery module into multiple independently connectable cell groups that can be configured in different series/parallel arrangements. By dividing the cells into modular groups with individual buss bars, the system enables flexible voltage configurations (e.g., different series connections) without requiring complete redesign, thus achieving adaptability while maintaining manageable complexity through standardized modular units.
Solution Approach 2:
The patent implements dynamic reconfigurability by designing buss bar connection systems that allow cells to be connected in different configurations. The modular buss bar design with configurable connection points enables the battery module to dynamically adapt its electrical architecture for different voltage requirements, transforming a static single-voltage system into a dynamic multi-voltage system.
3Adaptability or versatility
If multiple conventional battery modules are connected in series to provide different voltages, then voltage flexibility is improved, but battery size increases
Solution Approach 1:
The patent merges multiple cell groups and their associated buss bars into a single integrated battery module. By combining what would traditionally require multiple separate modules into one unified structure with internal configurability, the system achieves multi-voltage capability without increasing overall battery size. The integrated design allows different voltage configurations within the same physical footprint, eliminating the need for additional external modules.
4Device complexity
If conventional battery modules lack integrated cooling, then device complexity is reduced, but heat removal is insufficient
Solution Approach 1:
The patent applies multi-functionality by designing buss bars that serve dual purposes: electrical connection and thermal management. The buss bars are thermally coupled to heat sinks, allowing them to function both as electrical conductors connecting battery cells and as heat transfer pathways. This integration enables effective heat removal without adding separate dedicated cooling structures, thus maintaining structural simplicity while improving thermal management.
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 flexible voltage configurations, increased package density, effective heat management, and enhanced safety through compact fusing, addressing the limitations of conventional battery modules.
Implementation Method 1
The buss bars can include two portions made by different materials (e.g., an aluminum portion and a copper portion) that are welded together
Implementation Method 2
The buss bars can include two portions made by different materials (e.g., an aluminum portion and a copper portion) that are welded together
Implementation Method 3
A battery module can include heat sinks at one end or both ends for cooling the battery module via the buss bars
Implementation Method 4
Peripheral sides of the terminals are unobstructed by the buss bar segments such that a laser can be pointed toward the peripheral sides to weld the terminals to the buss bar segment
Data Source
AI summary
Exemplary embodiments of the present invention provide flexible, multi-voltage battery modules having multiple cells that are nested together. The cells can be, for example, cylindrical lithium ion cells. To increase cell package density, the cells can be disposed in a nested configuration so that adjacent cell centers form equilateral triangles. The cells can be placed in a housing or case with interlocking tabs that allow multiple modules to be connected together. Within a module, the cells can be connected in different configurations by buss bars at the top and the bottom of the battery cells. The different configurations may provide different voltages for the module.