Patterned Inter-Cell Coupling Materials for Uniform Battery Current
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Solution Overview
Problem
Conventional battery cell coupling materials face challenges in achieving a balance between conductive and adhesive properties, particularly in larger batteries, leading to issues with uniform current distribution and increased weight, as well as vulnerability to vibration and impact.
Innovation Solution
The use of patterned coupling materials, including non-conductive adhesives and metal-containing materials with controlled conductivity and high Young's modulus, allows for direct contact regions between current collectors, decoupling adhesive and conductive functionalities, and providing superior bonding strength and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coupling materials are used to connect battery cells, then adhesive properties are achieved, but conductive properties and uniform current distribution deteriorate
Solution Approach 1:
The coupling material is segmented into distinct functional regions: a non-conductive adhesive portion for bonding and a conductive portion for current transfer. This segmentation allows each region to optimize its specific function without compromising the other, resolving the contradiction between adhesive strength and current distribution uniformity.
Solution Approach 2:
Different regions of the coupling material are assigned different electrical conductivities: the adhesive portion is non-conductive to prevent parasitic current paths, while the conductive portion is specifically positioned to ensure uniform current distribution between cells. This local differentiation of properties resolves the contradiction.
2Strength
If conventional coupling materials are used to connect battery cells, then bonding is achieved, but weight increases
Solution Approach 1:
The coupling material is divided into discrete adhesive islands rather than a continuous layer, reducing the total amount of material required while maintaining bonding strength through strategic placement at critical contact points between cells.
Solution Approach 2:
The patent employs a thin-film coupling material that provides sufficient bonding and conductive functionality with minimal mass, effectively replacing heavier conventional coupling materials while maintaining performance.
3Strength
If conventional coupling materials are used to connect battery cells, then connection is achieved, but vulnerability to vibration and impact increases
Solution Approach 1:
The coupling material is a composite structure combining non-conductive adhesive regions for bonding with conductive regions for electrical connection. This composite design provides both mechanical strength for vibration/impact resistance and electrical functionality, resolving the contradiction between connection strength and reliability under dynamic conditions.
4Reliability
If patterned coupling materials are used, then current distribution uniformity is improved, but material selection range deteriorates
Solution Approach 1:
The coupling material is segmented into adhesive and conductive portions, allowing independent selection of materials for each function. This segmentation expands the material selection range by enabling optimization of each region's properties without being constrained by the requirements of the other region.
Solution Approach 2:
The composite structure of the coupling material allows combination of different material systems - non-conductive adhesives for bonding and conductive materials for current transfer - thereby expanding the overall material selection range while achieving superior current distribution uniformity.
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 approach enhances the range of suitable materials, ensures uniform current distribution, and improves the bonding strength and durability of batteries, especially in larger and more dynamic applications.
Implementation Method 1
The non-conductive adhesive may be coated discontinuously between the first current collector and the second current collector
Implementation Method 2
The metal-containing material may form a conductive bond between the first current collector and the second current collector
Implementation Method 3
The patterned coupling material may be characterized by a Young's modulus greater than or about 1,000 MPa
Data Source
AI summary
Batteries according to embodiments of the present technology may include a first battery cell including a first current collector. The batteries may include a second battery cell including a second current collector. The second battery cell may be vertically aligned with the first battery cell, and the second current collector may be positioned adjacent the first current collector. The first battery cell and the second battery cell may be electrically coupled together so the first battery cell and the second battery cell transfer current through the cells between the first current collector and the second current collector. The batteries may also include a patterned coupling material disposed between the first battery cell and the second battery cell and joining the first current collector with the second current collector.