Series-Connected Electrochemical Cell Stacks Without Bus Bars
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Solution Overview
Problem
Existing electrochemical cell systems fail to achieve high total voltage while remaining compact, easy to transport, and low-cost for high power applications such as electric vehicle batteries and solar energy systems.
Innovation Solution
The system consists of electrochemical cell stacks connected in series with semi-solid electrodes and a novel packaging design that eliminates the need for bus bars and welding equipment, allowing for flexible voltage levels and easy assembly, replacement, and transportability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electrochemical cells are arranged in stacks with series connections to achieve high total voltage, then the voltage output increases, but the system complexity and manufacturing difficulty increase
Solution Approach 1:
The system is divided into multiple electrochemical cell stacks, each containing a specific number of cells connected in series. Each stack is further segmented into individual cells with standardized configurations. This segmentation allows the system to achieve high voltage through modular stacking while maintaining manageable complexity at each level.
Solution Approach 2:
The electrochemical cells are designed with universal characteristics that allow them to serve multiple functions: individual energy storage units, series-connected voltage contributors, and modular components that can be arranged in different stack configurations. This universality enables the same cell design to achieve various voltage levels and power requirements without increasing inherent system complexity.
2Power
If electrochemical cell stacks are designed for high total voltage, then the power output increases, but the manufacturing cost increases
Solution Approach 1:
The manufacturing process is segmented into standardized steps for individual cell production, stack assembly, and system integration. Each cell is manufactured using consistent processes, and stacks are assembled by connecting predetermined numbers of cells in series. This segmentation enables economies of scale and reduces per-unit manufacturing costs while achieving high voltage outputs.
Solution Approach 2:
The system achieves different voltage levels by changing the number of cells per stack rather than redesigning the entire system. This parameter change approach allows flexible voltage configuration using the same standardized cell design and manufacturing processes, thereby controlling manufacturing costs while meeting various power requirements.
3Quantity of substance
If electrochemical cell stacks are configured for high power applications, then the energy density increases, but the transportability decreases
Solution Approach 1:
The high energy density system is segmented into modular stacks that can be independently handled and transported. Each stack contains a manageable number of cells connected in series, allowing the total energy capacity to be distributed across multiple transportable units. This segmentation maintains high overall energy density while improving transportability compared to a single large-scale high-voltage system.
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 configuration enables higher charge and discharge efficiency, increased energy density, and improved performance with reduced manufacturing complexity and cost, supporting higher load demands.
Implementation Method 1
a first electrically conductive plate including a first section and a second section, and a second electrically conductive plate. The first section of the first electrically conductive plate is in contact with a first terminal end of a first electrochemical cell stack from the plurality of electrochemical cell stacks. The second section of the first electrically conductive plate is in contact with a first terminal end of a second electrochemical cell stack from the plurality of electrochemical cell stacks.
Implementation Method 2
a plurality of electrochemical cell stacks each including a plurality of electrochemical cells connected in series
Data Source
AI summary
Embodiments described herein relate to electrochemical cells and multicells. A multicell can include a cell packaging that includes two or more electrochemical cells connected in series internal to the cell packaging. In some aspects, an apparatus includes a plurality of electrochemical cell stacks each including a plurality of electrochemical cells connected in series, a first electrically conductive plate including a first section and a second section, and a second electrically conductive plate. The first section of the first electrically conductive plate is in contact with a first terminal end of a first electrochemical cell stack from the plurality of electrochemical cell stacks. The second section of the first electrically conductive plate is in contact with a first terminal end of a second electrochemical cell stack from the plurality of electrochemical cell stacks.