Battery Cell Interconnect Assembly with Integrated Voltage Sensing
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Solution Overview
Problem
Existing battery cell interconnect and voltage sensing assemblies lack an efficient and reliable method to electrically and physically couple multiple battery cells in series while effectively routing voltage signals for accurate monitoring and management.
Innovation Solution
A battery cell interconnect and voltage sensing assembly utilizing a plastic frame member with elongated apertures and interconnect members, coupled with a wire harness assembly, to securely connect multiple battery cells in series and route voltage signals to a battery management system, enabling precise monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery cell interconnect methods are used, then assembly simplicity is maintained, but electrical connection reliability and voltage sensing accuracy deteriorate
Solution Approach 1:
The patent combines multiple functions into a single integrated assembly: the plastic frame member simultaneously provides structural support, electrical connection pathways, and voltage sensing capabilities. The interconnect members integrate mechanical fastening features with electrical contact surfaces, merging structural and electrical functions into unified components that improve reliability without proportionally increasing complexity
Solution Approach 2:
The plastic frame member serves multiple purposes: it acts as a structural support element, provides alignment features for battery cells, creates electrical connection pathways through its apertures, and supports voltage sensing terminals. This multi-functionality reduces the number of separate components needed while maintaining connection reliability
2Productivity
If multiple separate interconnect members are used to connect battery cells, then electrical connection flexibility is improved, but assembly time and manufacturing complexity increase
Solution Approach 1:
The interconnect structure is segmented into modular components (first interconnect member, second interconnect member, third interconnect member) that can be independently manufactured and then quickly assembled. Each segment handles specific battery cell connections, allowing for standardized, repeatable assembly operations that increase productivity while keeping individual component complexity manageable
Solution Approach 2:
The plastic frame member is pre-configured with apertures, ribs, and alignment features before assembly. The interconnect members are pre-positioned or pre-assembled onto the frame, so that during final battery module assembly, connections are made quickly without requiring complex on-site configuration or alignment procedures
3Measurement precision
If voltage sensing terminals are integrated into the interconnect assembly, then monitoring accuracy is improved, but manufacturing complexity increases
Solution Approach 1:
The voltage sensing terminals are integrated directly into the interconnect assembly structure rather than being separate components. The plastic frame member incorporates sensing terminals that electrically contact the battery cells through the same apertures used for mechanical interconnection, combining measurement functionality with structural elements to maintain manufacturing simplicity while improving voltage monitoring accuracy
Data Source
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AI summary
A battery cell interconnect and voltage sensing assembly is provided. The assembly includes a plastic frame member having a first side and a second side, and first, second, third and fourth elongated apertures extending therethrough. The assembly further includes an elongated interconnect member coupled to the plastic frame member and extends past both the first and third apertures. The elongated interconnect member is coupled to both a first electrical terminal of a first battery cell extending through the first elongated aperture, and a first electrical terminal of a second battery cell extending through the third elongated aperture. The elongated interconnect member has a spade lug coupled to a wire harness assembly.