Battery Cell Interconnector With Ultrasonic Welding Support
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Solution Overview
Problem
Battery cell electrodes are not mechanically supported during manufacture, leading to bending and degradation when mechanically fastened together.
Innovation Solution
A battery cell interconnect and voltage sensing assembly that includes a circuit board with slots and apertures, and an electrical interconnect member with side walls and tabs, which ultrasonically welds to the electrodes, providing mechanical support and electrical coupling between battery cell assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrodes are mechanically fastened together without support, then assembly is simple, but electrodes bend and become degraded
Solution Approach 1:
The patent introduces an interconnect structure with side walls that act as a mechanical intermediary between battery cells. These side walls provide support to the electrodes during assembly, preventing bending and degradation while enabling electrical connection. The interconnect serves as a mediator that simultaneously provides mechanical support and electrical conductivity, resolving the contradiction between assembly simplicity and electrode integrity.
Solution Approach 2:
The patent adds vertical side walls to the interconnect structure, transitioning from a flat 2D connection to a 3D structure. These side walls extend upward to contact and support the electrodes, providing mechanical support in a new dimensional direction. This dimensional change enables the interconnect to perform both electrical connection and mechanical support functions simultaneously.
2Strength
If mechanical fasteners are used to connect battery cells, then connection is achieved, but electrodes are not mechanically supported
Solution Approach 1:
The interconnect with extended side walls serves as a mediator structure that provides mechanical support to electrodes. The side walls contact the electrodes directly, distributing mechanical loads and preventing deformation, while the interconnect itself maintains strong electrical connections between battery cells. This intermediary structure simultaneously addresses both connection strength and electrode stability.
3Device complexity
If a simple mechanical fastening system is used, then device complexity is low, but voltage sensing capability is absent
Solution Approach 1:
The patent merges the electrical connection function and voltage sensing function into a single integrated interconnect structure. The same interconnect that provides mechanical support and electrical connection also incorporates voltage sensing capabilities through integrated contacts or traces. This merging eliminates the need for separate sensing components, maintaining low device complexity while adding measurement precision.
Solution Approach 2:
The interconnect structure is designed to perform multiple functions simultaneously: mechanical support for electrodes, electrical connection between cells, and voltage sensing. This multi-functionality allows the system to achieve voltage sensing accuracy without adding separate dedicated sensing components, thereby maintaining low overall device complexity while enhancing measurement capability.
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 assembly effectively supports battery cell electrodes, prevents degradation, and allows for electrical coupling and voltage sensing, enhancing the reliability and performance of battery packs.
Implementation Method 1
ultrasonically welding the first electrical terminal to the first side wall of the electrical interconnect member. The method further includes ultrasonically welding the second electrical terminal to the second side wall of the electrical interconnect member.
Data Source
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AI summary
A battery cell interconnect and voltage sensing assembly and a method for coupling a battery cell assembly thereto are provided. The battery cell interconnect and voltage sensing assembly includes a circuit board, electrical interconnect members, and an electrical connector. The circuit board further has slots therethrough for receiving the electrical interconnect members thereon. Electrical terminals from battery cell assemblies are coupled to the electrical interconnect members. The circuit board also has electrical traces for routing voltages at the electrical interconnect members to the electrical connector for sensing voltages of the battery cell assemblies.