Battery Assembly Using Housing Conduction for Voltage Sensing
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Solution Overview
Problem
Existing battery assembly methods for larger form-factor batteries with terminals separated by significant distances or located on different faces are complex and costly due to the need for long physical connections, which can introduce measurement errors and short circuit hazards.
Innovation Solution
An electric battery assembly design where the electronic unit is electrically connected to the battery cell housing, which acts as one terminal, eliminating the need for direct wiring between terminals, and using an insulator to isolate the second terminal, allowing for wireless data transmission and integration with a battery management system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long physical wires are used to connect the measurement device to both battery terminals, then electrical connection is established, but assembly complexity and cost increase significantly
Solution Approach 1:
The patent extracts one of the two required wire connections by utilizing the battery housing as an electrical conduit. The housing is electrically connected to one battery terminal and provides a path for the measurement device to access that terminal's electrical potential, eliminating the need for a separate wire to that terminal and reducing assembly complexity
Solution Approach 2:
The battery housing serves multiple functions: it provides mechanical protection for battery components, structural support, and simultaneously acts as an electrical conductor to transmit the electrical signal from one terminal to the measurement device, reducing the need for dedicated wiring
2Reliability
If long physical wires are used to connect the measurement device to both battery terminals, then electrical connection is established, but measurement accuracy deteriorates due to voltage drops
Solution Approach 1:
The battery housing acts as an intermediary electrical conductor between the battery terminal and the measurement device. By using the housing as the electrical pathway instead of long wires, the patent minimizes resistance and voltage drops, thereby improving measurement accuracy while maintaining reliable electrical connection
3Reliability
If long physical wires are routed between battery terminals and measurement device, then electrical connection is established, but short circuit hazards increase
Solution Approach 1:
The patent removes the hazardous element (long exposed wires) from the system by using the battery housing as the electrical pathway. This eliminates the risk of wire insulation failure, loose connections, or accidental contact that could cause short circuits, while maintaining the necessary electrical connection for measurement
4Device complexity
If the battery housing is used as an electrical terminal, then wiring complexity is reduced, but electrical insulation requirements become more critical
Solution Approach 1:
The patent applies local quality by providing electrical insulation only at specific critical locations where the housing's dual role as structural component and electrical conductor creates potential hazards. Insulators are placed at points where electrical isolation is necessary, such as between the housing and components that should not be electrically connected to the housing, rather than insulating the entire housing structure
Data Source
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AI summary
An electric battery assembly is disclosed comprising: a battery cell having an exterior housing and first and second electrical terminals enabling power to be drawn from the battery cell, the housing being electrically coupled to the first electrical terminal and electrically insulated from the second electrical terminal; an electronic unit comprising a measurement device; and wherein the electronic unit is electrically connected to the second electrical terminal and to the housing, thereby electrically coupling the electronic unit to the first battery cell terminal via the housing, enabling the measurement device to measure a property of the battery cell.