Offset Bus Bar Current Collectors for Battery Module Space Management
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Solution Overview
Problem
Conventional battery modules face challenges in efficient space management and cell cooling due to the need for electrical connections at both ends of the cells, which complicates the integration of current collectors and cooling systems.
Innovation Solution
The battery module design incorporates a first and second current collector, where the second current collector has an opening to receive the cell housing sidewall for direct electrical connection, allowing for parallel electrical connections and efficient cooling via a cell holder with integrated coolant channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current collectors are disposed at each of the opposed ends of the cells, then electrical connections are provided at both terminals, but space management becomes challenging and cell cooling via immersion is difficult
Solution Approach 1:
The patent transitions from a conventional configuration where current collectors are placed at opposite ends of cells (one-dimensional arrangement) to a novel configuration where both current collectors are positioned at the same end of the cells (two-dimensional arrangement). This dimensional change allows both positive and negative current collectors to access terminals at a single location, simplifying space management while maintaining electrical connection reliability. The cell holder structure further enables vertical stacking of cells with current collectors at the top, creating a multi-layered spatial organization that resolves the space management challenge.
2Reliability
If current collectors are disposed at each of the opposed ends of the cells, then electrical connections are provided at both terminals, but integration of cooling systems becomes complicated
Solution Approach 1:
The patent merges the electrical connection function and cooling function into a single integrated structure at one end of the cells. The cell holder not only provides mechanical support and electrical connection pathways for both current collectors but also incorporates coolant flow channels directly into its structure. This consolidation of multiple functions (electrical connection, mechanical support, and thermal management) into a single integrated component significantly simplifies manufacturing and assembly compared to separate components for each function.
Solution Approach 2:
The cell holder is designed as a multi-functional component that simultaneously performs electrical connection, mechanical support, and thermal management functions. By making the cell holder universal in its capabilities, the patent eliminates the need for separate specialized components, thereby simplifying the overall system architecture and manufacturing process while maintaining reliable electrical connections and effective cooling.
3Reliability
If conventional battery module design is used with current collectors at opposed ends, then electrical connections are established, but space utilization is inefficient
Solution Approach 1:
The patent reorganizes the spatial arrangement from a linear one-dimensional layout (current collectors at opposite ends along the cell length) to a two-dimensional configuration (both current collectors at the same end with vertical cell stacking). This dimensional reorganization dramatically improves space utilization by allowing cells to be stacked vertically in the cell holder, thereby reducing the overall module volume required for a given battery capacity while maintaining all necessary electrical connections.
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 enhances space management and cooling efficiency by enabling parallel electrical connections and direct cell housing contact, facilitating easier integration and effective cooling within the battery module.
Implementation Method 1
cell cooling via immersion in a liquid coolant
Implementation Method 2
coolant channels
Data Source
AI summary
A battery system includes a pair of current collectors that are configured to provide a parallel electrical connection between electrochemical cells of a cell array. The pair of current collectors includes a first current collector plate that provides an electrical connection between the ends of the respective cells, and a second current collector plate that includes openings that receive the cells therein, and provide an electrical connection between the sidewalls of the respective cells. The current collectors are each on the same end of the cells and the opposed end of the cell can be protected or electrically isolated for a multitude of functions, such as cell cooling.