Pouch Cell Capacitance Measurement via Direct Foil Connection

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Solution Overview

Problem

Conventional battery monitoring systems rely on capacitive coupling for capacitance measurements, which often results in imprecise and inaccurate readings, affecting the reliability of battery health monitoring and quality control.

Innovation Solution

The system employs a direct electrical connection between an external conductive material and a conductive foil in the battery cell pouch for capacitance measurements, eliminating the need for capacitive coupling and enhancing measurement accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If capacitive coupling is used for capacitance measurements, then the measurement process can be implemented, but the measurement precision and accuracy deteriorate

Engineering Contradiction:

Improvecapacitance measurement accuracyVSAvoidmeasurement system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the capacitive coupling interface from the measurement system by implementing direct electrical connection through exposed conductive layers. This removes the intermediate coupling mechanism that caused measurement inaccuracies, allowing direct contact between measurement electrodes and battery cell conductive layers.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an exposed conductive layer as a direct intermediary between the measurement system and battery cell components. This conductive layer serves as a permanent electrical contact point that eliminates the need for capacitive coupling, providing stable and accurate measurement pathways.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If direct electrical connection is implemented, then measurement accuracy improves, but manufacturing complexity increases

Engineering Contradiction:

Improvecapacitance measurement accuracyVSAvoidbattery cell manufacturing

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent merges the measurement contact function with the existing conductive foil layer structure of the battery cell. By exposing portions of the conductive foil that already exist in the battery construction, the system achieves direct electrical connection without adding separate contact components, thus maintaining manufacturing simplicity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductive foil layer serves multiple functions: it provides electrical connectivity for battery operation and simultaneously serves as the measurement contact point for capacitance measurements. This multi-functionality eliminates the need for separate measurement electrodes or complex connection mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If conventional capacitive coupling is used, then the measurement system can operate, but reliability of battery health monitoring deteriorates

Engineering Contradiction:

Improvebattery health monitoring reliabilityVSAvoidmeasurement operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent removes the capacitive coupling mechanism that introduced measurement errors and reliability issues. By implementing direct electrical connection through exposed conductive layers, the system eliminates the intermediate coupling that caused inconsistent readings, thereby improving the reliability of battery health monitoring.

Inventive Principle:

Principle #2Taking out (Extraction)

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 increases the sensitivity and accuracy of capacitance measurements, simplifies the measurement process, and reduces costs, enabling more reliable battery quality control, state of health monitoring, and early detection of thermal runaway.

Implementation Method 1

a conductive portion arranged adjacent to the outer layer and directly connected to the exposed portion of the inner layer

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 2

The capacitance measurement module is configured to measure capacitance values between the conductive portion of the at least one pouch-type battery cell and at least one of the first battery terminals and the second battery terminals

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS20250158254A1Battery monitoring systems with direct electrical connection for capacitance measurement in battery cells

Publication Date: 2025.05.15 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery cell includes a battery cell enclosure having an inner layer made of an electrically conductive material and an outer layer made of an electrically insulative material. A portion of the inner layer is exposed. The battery cell further includes first battery terminals arranged in the battery cell enclosure, second battery terminals arranged in the battery cell enclosure, electrolyte located between the first battery terminals and the second battery terminals, and a conductive portion arranged adjacent to the outer layer and directly connected to the exposed portion of the inner layer. Other example battery cells, battery systems with capacitance measurement modules, and methods for measuring capacitance values associated with battery cells are also disclosed.