Roller Interconnect for Battery Cell Tab Electrodes
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Solution Overview
Problem
There is a need for improved battery systems in xEVs that enhance travel distance, performance, and reduce costs, particularly in integrating lithium ion battery cells with traditional vehicle platforms, while addressing packaging and efficiency challenges.
Innovation Solution
The development of lithium ion battery modules with a roller housing structure and roller interconnect assemblies for secure and easy connection of tab electrodes, enabling series or parallel electrical coupling, and a DC-to-DC converter for providing multiple voltage levels within a standardized lead acid battery form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If traditional battery systems are used in xEVs, then vehicle platform compatibility is maintained, but travel distance and performance are limited
Solution Approach 1:
The battery system is divided into modular battery cells that can be independently connected through interconnect assemblies. This segmentation allows flexible configuration of multiple cells to achieve higher capacity and extended travel distance while maintaining compatibility with existing vehicle platforms through standardized mounting interfaces and electrical connections.
2Duration of action of moving object
If lithium ion battery cells are integrated into traditional vehicle platforms, then travel distance and performance improve, but packaging efficiency challenges arise
Solution Approach 1:
The interconnect assembly is designed with a roller housing structure that receives and secures tab electrodes from adjacent battery cells. The roller is disposed within an opening defined by the roller housing structure, creating a nested configuration where components are efficiently packed together. This nesting approach maximizes space utilization and improves packaging efficiency while accommodating high-capacity lithium ion cells.
3Reliability
If battery cells are connected using traditional interconnection methods, then electrical coupling is achieved, but connection security and ease of assembly are compromised
Solution Approach 1:
The interconnect assembly incorporates a roller that can be inserted into and removed from the roller housing structure opening. This dynamic design allows for easy assembly and disassembly of battery cells while maintaining secure electrical connections during operation. The roller's movement capability simplifies manufacturing and assembly processes compared to permanent or complex fastening methods.
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 solution extends the travel distance of xEVs, improves battery performance, and reduces costs by integrating lithium ion technology into traditional vehicle platforms with enhanced packaging efficiency and thermal management, while maintaining compatibility with existing systems.
Implementation Method 1
The roller may be sized to exert a force on the roller housing structure when inserted into the opening defined by the roller housing structure to hold the tab electrodes therebetween via a friction fit.
Data Source
AI summary
A battery module includes a power assembly including a first battery cell and a second battery cell in a stacked orientation relative to each other. The first battery cell includes a first tab electrode extending therefrom, and the second battery cell includes a second tab electrode extending therefrom. The battery module also includes an interconnect assembly configured to facilitate electrically coupling the first tab electrode with the second tab electrode. The interconnect assembly includes a roller housing structure about which the first and second tab electrodes at least partially conform such that the first and second tab electrodes are positioned in an opening defined by the roller housing structure. The interconnect assembly also includes a roller disposed in the opening of the roller housing structure such that the first and second tab electrodes are secured in electrical communication.