Battery Cell Interconnector with Encapsulated Circuit Board
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Solution Overview
Problem
Current battery cell interconnect and voltage sensing assemblies lack effective encapsulation and robust mechanical connections, leading to vulnerability against liquids and mechanical stress, and inefficient voltage sensing mechanisms.
Innovation Solution
A battery cell interconnect and voltage sensing assembly featuring a frame member with a central plate and support members, coupled with a circuit board and electrical interconnect members, where the assembly includes an encapsulation portion that bonds to the circuit board, providing mechanical shock and vibration protection, electrical isolation, and preventing liquid contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the circuit board is attached to the frame member without encapsulation, then the assembly structure is simple, but the circuit board is vulnerable to liquids and mechanical stress
Solution Approach 1:
An encapsulation portion is provided that encapsulates the circuit board, protecting it from liquids and mechanical stress. The encapsulation portion acts as a protective shell that seals the circuit board while allowing the assembly to maintain its functional complexity through integrated design.
Solution Approach 2:
The encapsulation portion is integrated with the frame member and circuit board assembly, combining protective functionality with the structural elements. This merging approach protects the circuit board while avoiding the need for separate, additional protective components that would increase assembly complexity.
2Strength
If mechanical connections are made robust with multiple components, then mechanical strength is improved, but the assembly becomes more complex and harder to manufacture
Solution Approach 1:
The frame member includes pre-formed support members and coupling tabs that are integrated into the frame structure during frame manufacturing. These features are prepared in advance to receive and secure the electrical interconnect members and circuit board, eliminating the need for additional assembly steps to create mechanical connections.
Solution Approach 2:
The support members serve multiple functions: they provide mechanical support for the electrical interconnect members, maintain proper spacing, and facilitate secure attachment. This multi-functionality reduces the number of separate components needed while maintaining robust mechanical connections.
3Measurement precision
If voltage sensing tabs extend through multiple components, then voltage sensing capability is improved, but the assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The voltage sensing function is segmented into distinct components: voltage sensing tabs on the electrical interconnect members, apertures in the frame member and circuit board, electrical traces on the circuit board, and an electrical connector. This segmentation allows each component to be optimized independently while working together to achieve precise voltage sensing.
Solution Approach 2:
The voltage sensing path extends through multiple dimensions and layers of the assembly, from the electrical interconnect members through the frame member and circuit board to the electrical connector. This multi-dimensional arrangement enables voltage sensing while distributing the functional requirements across different spatial planes.
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 solution enhances mechanical robustness, electrical isolation, and prevents contamination, allowing for reliable voltage sensing and improved performance in battery cell interconnects.
Implementation Method 1
an encapsulation portion that is bonded to and encapsulates the first and second sides of the circuit board
Data Source
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AI summary
A battery cell interconnect and voltage sensing assembly and method are provided. The assembly includes a frame member having a rectangular ring-shaped peripheral wall with first, second, third and fourth wall portions. The frame member further includes a central plate portion. The assembly further includes an electrical interconnect member electrically that is coupled to an electrical terminal of a battery cell. The electrical interconnect member has a tab that extends through an aperture in the central plate portion. The assembly further includes a circuit board and an encapsulation portion that is bonded to and covers a side of the circuit board.