Battery Cell Interconnect Panels for Simpler Module Assembly
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Solution Overview
Problem
Conventional battery modules are difficult to manufacture and require complicated procedures and specialized machinery, necessitating an improved interconnect system for simpler and less expensive production.
Innovation Solution
A battery module with a housing, battery cells, a monitoring module, and a battery interconnect system (BIS) that includes upper and lower interconnect panels, insulating layers, and a carrier, all made from conductive metals and thermoplastic resins, allowing for efficient connection and monitoring of battery cells with simplified assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery cell interconnection methods are used, then reliable electrical connection between battery cells is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple functions into the interconnect structure: electrical connection, mechanical support, and thermal management pathways are integrated into a single component system. The interconnect serves as both an electrical conductor and a structural element that maintains cell spacing and alignment, eliminating the need for separate connection components and reducing manufacturing steps.
Solution Approach 2:
The interconnect structure is designed to perform multiple functions simultaneously: providing electrical pathways for current flow, maintaining mechanical alignment between cells, enabling thermal conduction between adjacent cells, and facilitating modular assembly. This multi-functionality reduces the number of components needed and simplifies the overall manufacturing process.
2Volume of moving object
If battery cells are arranged closely together for compact design, then space efficiency improves, but risk of damage and excessive heating between adjacent cells increases
Solution Approach 1:
The interconnect structure incorporates localized thermal management features at critical interfaces between adjacent battery cells. Thermal pathways are concentrated at specific contact points where heat generation is most likely, providing targeted heat dissipation exactly where needed while maintaining close cell spacing for compactness.
Solution Approach 2:
The interconnect acts as an intermediary thermal pathway between adjacent battery cells. Instead of allowing direct thermal contact that could lead to uncontrolled heat transfer and damage, the interconnect provides a controlled thermal conduit that manages heat flow between cells, dissipating excess heat while maintaining the close spacing required for compact module design.
3Reliability
If individual fusing is implemented for each battery cell, then cell protection against short circuits is improved, but manufacturing procedures become more complicated
Solution Approach 1:
The patent integrates protective fusing functionality directly into the interconnect structure itself, rather than requiring separate fusing components for each cell. The interconnect is designed with inherent protective features that provide short circuit protection across multiple cells simultaneously, reducing the number of manufacturing steps and components while maintaining comprehensive cell protection.
Data Source
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AI summary
A battery module having a plurality of battery cells disposed in a housing and interconnected by upper and lower interconnect panels stamped from sheets of conductive metal. Each of the upper and lower interconnect panels have a plurality of contacts secured to terminals of the battery cells, respectively. The contacts are at least partially disposed in panel openings extending through the upper and lower interconnect panels. A carrier is provided and includes a lead frame molded into a body of thermoplastic resin. The lead frame connects a plurality of locations on the upper and lower interconnect panels to a monitoring module that measures physical properties at the locations.