Thermal Interconnects for Energy Storage Devices
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Solution Overview
Problem
Existing energy storage devices, particularly electrochemical double layer capacitors, face challenges with high equivalent series resistance, which limits charge and discharge rates, and requires complex and costly manufacturing processes for customizable modules with efficient heat conduction and structural rigidity.
Innovation Solution
The method involves laser welding a cylindrical aluminum housing to the current collector foil of a jellyroll electrode assembly, using a zig-zag pattern to reduce resistance and enhance contact robustness, and employing a configurable enclosure with interlocking panels and thermal pads for customizable module designs that can be easily assembled from standardized components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods are used to connect energy storage devices, then assembly is straightforward, but equivalent series resistance is high and contact robustness is poor
Solution Approach 1:
The patent replaces conventional mechanical welding methods with laser welding technology. The laser welding process uses a focused laser beam to melt and fuse the aluminum housing and current collector foil, creating a more robust and reliable electrical connection with lower equivalent series resistance compared to traditional mechanical welding methods.
Solution Approach 2:
The patent changes the welding parameters by using laser welding instead of conventional methods, which alters the heating pattern, melting characteristics, and cooling rates. This parameter change results in a more reliable electrical connection with reduced contact resistance and improved contact robustness.
2Adaptability or versatility
If standardized components are used for module assembly, then manufacturing cost and complexity are reduced, but customization capability is limited
Solution Approach 1:
The patent designs the enclosure with interlocking panels that can be configured in multiple arrangements to accommodate different numbers and configurations of energy storage devices. The standardized panels serve multiple functions: structural support, thermal conduction, and customizable configuration, allowing the same basic components to create various module designs.
Solution Approach 2:
The enclosure is divided into multiple standardized panels that can be independently assembled and configured. This segmentation allows for flexible customization of module designs by combining different numbers and arrangements of standardized panels, reducing overall system complexity while maintaining adaptability.
3Temperature
If complex manufacturing processes are used to achieve efficient heat conduction, then thermal efficiency is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines structural support and thermal conduction functions into the enclosure panels themselves. The panels are made from thermally conductive materials and are directly coupled to the energy storage devices, eliminating the need for separate thermal management components and simplifying manufacturing while achieving efficient heat conduction.
Solution Approach 2:
The enclosure panels serve multiple functions simultaneously: providing structural support, enabling thermal conduction, and allowing for customizable configuration. This multi-functionality reduces the need for additional specialized components, simplifying manufacturing while maintaining efficient heat conduction.
4Reliability
If laser welding is used to reduce equivalent series resistance, then electrical performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The laser welding process applies heat locally and precisely to the specific areas where the aluminum housing and current collector foil need to be joined. This localized heating minimizes thermal distortion and maintains high manufacturing precision, enabling the achievement of low equivalent series resistance without requiring excessive overall manufacturing precision.
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 reduces equivalent series resistance, enhances module durability, and allows for customizable, lightweight, and thermally efficient energy storage solutions with reduced manufacturing complexity and cost.
Implementation Method 1
laser welding a cylindrical aluminum housing to the current collector foil of a jellyroll electrode assembly
Implementation Method 2
laser welding... using a zig-zag pattern
Data Source
AI summary
A thermally fitted interconnect couples energy storage cells without the use of additional materials of fasteners. Variations of the interconnect can be used to facilitate fitting of multiple energy storage cell with multiple cell to cell spacings in a rapid and inexpensive manner.