Flexible Battery Cell Interconnect with V-Shaped Clamps
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Solution Overview
Problem
Existing battery cell interconnect systems are not adaptable to the rapidly changing configurations and materials of battery cells, such as size, shape, and electrode spacing, which can lead to unreliable electrical connections in diverse applications like motorized vehicles and aircraft, where environmental factors like movement and temperature extremes cause degradation.
Innovation Solution
A flexible and scalable battery cell interconnection system featuring a conductive interconnect with offset termination ends, V-shaped terminal clamps, and insulating sleeves, using materials like aluminum or copper, to securely connect battery cells with varying configurations, ensuring durable and efficient electrical contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional rigid interconnect systems are used to connect battery cells, then structural stability is maintained, but adaptability to varying battery cell configurations (size, shape, electrode spacing) deteriorates
Solution Approach 1:
The interconnect system employs flexible conductive material that can dynamically adapt its shape and configuration to accommodate varying battery cell dimensions, electrode spacing, and arrangements. This dynamic flexibility allows the same interconnect design to work across multiple battery configurations without requiring complex adjustable mechanisms
Solution Approach 2:
The interconnect system is designed with universal applicability through its flexible conductive structure that can serve multiple battery cell types and configurations simultaneously. The system provides multi-functional capability by adapting to different cell sizes, shapes, and electrode arrangements while maintaining reliable electrical connection
2Reliability
If durable interconnects are designed to withstand environmental forces and corrosion, then reliability in harsh environments is improved, but manufacturing flexibility deteriorates
Solution Approach 1:
The interconnect system utilizes composite construction combining flexible conductive material with protective insulating coating. This composite structure provides both the flexibility needed for manufacturing adaptability and the environmental durability required for reliable operation in harsh conditions including corrosion resistance and mechanical strength
Solution Approach 2:
The system achieves manufacturing flexibility by being able to change its physical parameters such as bending radius, contact pressure, and configuration shape to accommodate different assembly requirements, while the protective coating maintains environmental durability throughout these parameter changes
3Productivity
If battery cell configurations are rapidly changed to improve performance, then output and capacity are improved, but interconnect reliability deteriorates
Solution Approach 1:
The flexible conductive interconnect can dynamically adapt to changing battery cell configurations as performance requirements evolve. This dynamic capability ensures reliable electrical connection whether the battery uses traditional configurations or emerging designs with different electrode arrangements and cell dimensions
4Adaptability or versatility
If flexible conductive material is used to accommodate varying cell configurations, then adaptability is improved, but contact resistance increases
Solution Approach 1:
The interconnect uses composite material construction with flexible conductive core maintaining low electrical resistance while outer protective layers provide environmental durability. This composite approach allows configuration flexibility without compromising electrical performance or contact resistance
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
The system provides reliable and efficient electrical connections across a range of battery cell configurations, reducing resistive heating and maintaining low contact resistance, suitable for forming battery modules and packs with high output and capacity for EV and HEV applications.
Implementation Method 1
A flexible and scalable battery cell interconnection system featuring a conductive interconnect with offset termination ends, V-shaped terminal clamps, and insulating sleeves, using materials like aluminum or copper, to securely connect battery cells with varying configurations, ensuring durable and efficient electrical contacts
Implementation Method 2
The system also includes a pair of V-shaped conductive terminal clamps, each terminal clamp having a pair of intersecting legs, each having a contact surface thereon, and a pair of spaced bores disposed at an intersection of the legs, each V-shaped terminal clamp operative for disposition on respective ones of the spaced rods through respective ones of the spaced bores
Implementation Method 3
an insulating sleeve disposed on an outer surface of the conductive interconnect over the intermediate portion
Data Source
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Figure 3
Figure 4~5
AI summary
A flexible and adaptable battery cell interconnection system is provided for interconnecting a plurality of battery cells. The battery cell interconnect system, includes a conductive interconnect having a first termination end and second termination end, the first termination end offset from the second termination end and separated therefrom by an intermediate portion, a pair of spaced threaded rods disposed on each of the first termination end and the second termination end, and an insulating sleeve disposed on an outer surface of the conductive interconnect over the intermediate portion. The system also includes a pair of V-shaped conductive terminal clamps, operative for disposition on respective ones of the spaced rods through respective ones of the spaced bores and a plurality of threaded nuts operative for disposition on each of the threaded rods, wherein the terminal clamps are operative for clamping a plurality of battery cell electrodes.