Series-Stacked Battery Cell Layout for Higher Voltage Density

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Solution Overview

Problem

Conventional battery cells have limited operational voltage, making it difficult to achieve high-voltage applications efficiently, as they require a large number of cells and increased mass and volume for battery packs.

Innovation Solution

The battery cell apparatus includes multiple electrode layer stacks electrically coupled in series, increasing the operational voltage to 6.4V or greater, allowing for fewer cells to achieve high-voltage applications while optimizing space and reducing mass and volume in battery packs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If conventional battery cells with single electrode layer stacks are used, then the battery cell structure is simple and easy to manufacture, but the operational voltage is limited and cannot achieve high-voltage applications efficiently

Engineering Contradiction:

Improveoperational voltageVSAvoidbattery cell structure

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The battery cell is divided into multiple electrode layer stacks (first electrode layer stack, second electrode layer stack, etc.) that are electrically coupled in series. Each stack is separated by insulative members and positioned within the same housing, allowing the battery cell to achieve high voltage (6.4V or greater) while maintaining a structured and organized internal configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple electrode layer stacks are combined within a single battery cell housing and electrically connected in series through tabs and connectors. This merging of multiple stacks into one integrated cell structure achieves high-voltage performance while reducing the total number of separate battery cells needed in a battery pack.

Inventive Principle:

Principle #5Merging (Combining)

2Power

If multiple battery cells are used to achieve high-voltage applications, then the required voltage can be obtained, but the mass and volume of the battery pack increase

Engineering Contradiction:

Improveoperational voltageVSAvoidbattery pack mass

Core Design Contradiction:

PowerVSWeight of stationary object

Solution Approach 1:

Multiple electrode layer stacks are merged into a single battery cell, eliminating the need for multiple separate battery cells to achieve the same voltage. This reduces the total mass and volume of the battery pack while maintaining the required operational voltage for high-voltage applications.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery cell utilizes vertical stacking of multiple electrode layer stacks within the same housing volume, effectively using the vertical dimension to increase voltage output without proportionally increasing the horizontal footprint or overall battery pack volume.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Power

If multiple battery cells are used to achieve high-voltage applications, then the required voltage can be obtained, but the physical footprint of the battery pack increases

Engineering Contradiction:

Improveoperational voltageVSAvoidbattery pack volume

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

Multiple electrode layer stacks are combined within a single battery cell housing, reducing the total number of separate cell housings needed. This consolidation decreases the overall battery pack volume and physical footprint while achieving the required high-voltage performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Multiple electrode layer stacks are nested within the same battery cell housing, with each stack positioned vertically or in layers. This nesting arrangement maximizes the use of internal space and reduces the external volume required compared to having separate housings for each stack.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Productivity

If multiple electrode layer stacks are electrically coupled in series within a single battery cell, then high-voltage applications are achieved with fewer cells, but the battery cell structure becomes more complex

Engineering Contradiction:

Improvepower densityVSAvoidbattery cell structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The battery cell is segmented into distinct electrode layer stacks with clear electrical connections between them. Insulative members are positioned between stacks to prevent short circuits, and tabs are systematically connected to form series circuits. This structured segmentation manages complexity while achieving high power density.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Insulative members and connectors act as intermediaries between electrode layer stacks, enabling electrical coupling while maintaining physical separation. These intermediary components facilitate the series connection of multiple stacks without requiring complex direct connections, thereby managing structural complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20240170811A1Battery cell apparatus

Publication Date: 2024.05.23 RIVIAN HOLDINGS LLC

AI summary

A battery cell apparatus can include a first electrode layer stack positioned within a housing, a first tab of the first electrode layer stack, a second tab of the first electrode layer stack coupled with a first terminal. The battery cell apparatus can include a second electrode layer stack positioned within the housing and a first tab of the second electrode layer stack coupled with the first tab of the first electrode layer stack. The first electrode layer stack can be electrically insulated from the second electrode layer stack.