Battery Conductor Plate Assembly With Fusible Links for Thermal Runaway
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Solution Overview
Problem
Existing automotive battery designs face challenges with wire bonding, which increases electrical resistance, manufacturing time, and cost, and requires significant rework, posing safety risks due to thermal runaway.
Innovation Solution
Implementing a conductor plate assembly with fusible and non-fusible links to provide electrical connections between battery cells, where fusible links act as fuses to prevent thermal runaway by breaking connections when overheating occurs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonds are used to connect battery cells, then electrical connections can be established between cells, but pack level electrical resistance increases and manufacturing time increases
Solution Approach 1:
The patent merges the connection function into the conductor plate itself by integrating tabs directly onto the plate structure. Multiple battery cells are connected to the same conductor plate simultaneously through multiple welds, eliminating the need for separate wire bonds between each cell. This combining approach reduces the total number of connection steps and materials while maintaining electrical connectivity.
Solution Approach 2:
The conductor plate serves multiple functions simultaneously: it provides electrical connection between cells, acts as a structural support element, and enables parallel connection of multiple cells through its integrated tabs. This multi-functionality eliminates the need for separate wire bond components and reduces overall assembly complexity.
2Reliability
If wire bonds are used to connect battery cells, then electrical connections can be established between cells, but manufacturing cost increases due to low yield and rework requirements
Solution Approach 1:
The patent combines multiple connection functions into a single conductor plate assembly, reducing the total number of components and assembly steps. By welding multiple cells directly to the plate simultaneously rather than using sequential wire bonding, the process achieves higher yield with fewer defects and minimal rework requirements.
Solution Approach 2:
The conductor plate with integrated tabs creates a standardized, repeatable connection pattern that can be consistently replicated across all battery assemblies. This standardization enables automated manufacturing processes with high precision and consistent quality, reducing variability and rework.
3Reliability
If wire bonds are used to connect battery cells, then electrical connections can be established, but significant rework is required when failures occur
Solution Approach 1:
The conductor plate is designed with segmented tabs that can be independently welded to individual battery cells. This segmentation allows for selective replacement or repair of specific cell connections without affecting the entire battery assembly, facilitating easier maintenance and repair operations.
4Object-affected harmful factors
If fusible links are implemented in the conductor plate assembly, then thermal runaway can be prevented by breaking connections during overheating, but device complexity increases
Solution Approach 1:
The fusible links are designed to fail in a controlled manner during thermal runaway events, converting the harmful thermal energy into a protective action. When excessive heat is detected, the fusible material melts and breaks the electrical connection, isolating the affected cell and preventing further thermal propagation. This controlled failure mode transforms a potential hazard into a safety mechanism.
Solution Approach 2:
The fusible link material acts as an intermediary between the electrical connection and the thermal runaway event. It provides a controlled failure point that responds to thermal stress by melting and breaking the circuit, thereby mediating the transition from normal operation to safety isolation without requiring complex external monitoring systems.
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
This solution reduces manufacturing time and cost, enhances safety by preventing thermal runaway, and improves manufacturing yield while maintaining electrical performance.
Implementation Method 1
fusible links at the at least one second conductor plate for connecting the at least one second conductor plate to multiple battery cells
Implementation Method 2
a first conductor plate assembly providing an electrical connection between the plurality of battery cells
Data Source
AI summary
A conductor plate assembly for providing an electrical connection between a plurality of battery cells of a battery package for an electric vehicle is described. The conductor plate assembly includes a plurality of first conductor plates, at least one second conductor plate, a plurality of fusible links at the at least one second conductor plate configured to connect the at least one second conductor plate to multiple battery cells, and a plurality of non-fusible links at the plurality of first conductor plates configured to connect the plurality of first conductor plates to plural battery cells. Related apparatuses, systems, and methods are also described.