Zigzag Battery Cell Layout for Compact High-Capacity Packs
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Solution Overview
Problem
Existing battery pack designs face challenges in miniaturization and achieving high-capacity output while maintaining a compact size.
Innovation Solution
The battery pack is configured with battery cells arranged in a zigzag pattern along a second axis, connected through a series of parallel and series connections, including first, second, and third parallel connections, which allow for efficient electrical connections and increased cell count within a limited space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged in a conventional grid pattern, then the structure is simple and easy to manufacture, but the battery pack size is larger and capacity is lower
Solution Approach 1:
The patent transitions from a conventional two-dimensional grid arrangement to a three-dimensional stacked configuration. Battery cells are arranged in multiple layers (first stack, second stack, third stack) with different connection patterns in each layer. This vertical stacking approach increases the number of cells that can be packed into a given volume, thereby increasing capacity without proportionally increasing the footprint area.
Solution Approach 2:
The battery pack is divided into multiple independent stacks (first stack, second stack, third stack), each containing a specific number of cells arranged in particular connection patterns. This segmentation allows for optimized space utilization in each stack and enables flexible configuration to maximize capacity within the available volume.
2Quantity of substance
If more battery cells are connected in parallel to increase capacity, then the electrical connections become more complex, but the device complexity must be managed
Solution Approach 1:
The connection architecture moves from planar two-dimensional routing to three-dimensional vertical connections between stacks. Collectors are positioned at different vertical levels to facilitate parallel connections between cells in different stacks, reducing the complexity of inter-cell wiring by utilizing the vertical dimension for current collection and distribution.
Solution Approach 2:
Collectors serve as intermediary components that facilitate electrical connections between multiple battery cells. The first collector and second collector act as intermediate connection points, simplifying the wiring architecture by providing centralized collection points for parallel-connected cells rather than requiring direct point-to-point connections between all cells.
Data Source
AI summary
A battery pack includes battery cells arranged along rows parallel to a first axis, the battery cells arranged in adjacent rows along a second axis crossing the first axis being misaligned with each other along the first axis; and a connection member configured to electrically connect the battery cells and form parallel modules, wherein the parallel modules include: a first parallel connection connecting first and second battery cells in adjacent rows; a second parallel connection connecting third and fourth battery cells in adjacent rows; and a third parallel connection connecting a pair of battery cells in a same row. The battery pack according to an embodiment may be advantageous for miniaturization and may provide a high-capacity output.