Battery Interconnect Structure With Integrated Fuse Links
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Solution Overview
Problem
Conventional battery pack interconnects using rigid metal plates are costly, complex, and prone to breakage under stress and vibration, leading to reliability and safety issues, while flexible interconnects face limitations in carrying high currents and forming controlled fusible links.
Innovation Solution
The development of interconnects comprising a conductor with electrically isolated portions, insulators, and fusible links, where the insulator has openings to support the conductor and allow for controlled fuse operation, and a temporary substrate for mechanical support during assembly, enabling robust and efficient electrical connections between battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rigid metal plates are used for interconnecting battery cells, then structural strength and current carrying capability are improved, but cost and manufacturing complexity increase
Solution Approach 1:
The rigid metal plate is segmented into multiple flexible interconnects, each consisting of a conductor with insulator layers. This segmentation allows each interconnect to be independently manufactured and assembled, reducing overall manufacturing complexity while maintaining structural strength through the distributed arrangement of multiple interconnects between battery cells
Solution Approach 2:
The interconnect uses a composite structure combining a conductive material (aluminum or copper) with insulating materials (polymer layers). This composite approach provides both electrical conductivity for current carrying and mechanical flexibility, replacing the single-material rigid metal plate solution
2Power
If rigid metal plates are used for interconnecting battery cells, then current carrying capability is improved, but cost increases
Solution Approach 1:
The conductor thickness is optimized to balance current carrying capability with cost. By carefully selecting the thickness parameter of the aluminum or copper conductor, the interconnect achieves sufficient power handling while using less expensive materials compared to traditional rigid metal plates
3Reliability
If conventional fuse wires are used to protect battery cells, then safety against over-current is improved, but reliability under stress and vibration deteriorates
Solution Approach 1:
The fuse function is merged with the interconnect structure itself. The conductor portion of the interconnect is designed to act as the fuse element, eliminating the need for separate fragile fuse wires. This integration ensures that the protective function is provided by the same robust structure that connects the battery cells, improving reliability under stress and vibration
4Ease of operation
If individual plates are attached to cells as separate components, then ease of assembly is improved, but manufacturing cost and complexity increase
Solution Approach 1:
Multiple functions are merged into the interconnect: electrical connection, mechanical support, insulation, and fuse protection are all integrated into a single component. This reduces the number of separate parts that need to be assembled, simplifying the manufacturing process while maintaining ease of assembly through the interconnect's inherent design features
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 provides a cost-effective, reliable, and robust interconnect system capable of handling high currents, reducing manufacturing complexity and improving safety by minimizing mechanical stress and enhancing the durability of battery pack connections.
Implementation Method 1
an insulator adhered to the conductor and mechanically supporting the two portions of the conductor
Implementation Method 2
a fuse forming an electrical connection between these two contacts
Implementation Method 3
a conductor comprising two or more portions electrically isolated from each other
Data Source
AI summary
Provided are interconnects for interconnecting a set of battery cells, assemblies comprising these interconnects, methods of forming such interconnects, and methods of forming such assemblies. An interconnect includes a conductor comprising two portions electrically isolated from each other. At least one portion may include two contacts for connecting to battery cells and a fuse forming an electrical connection between these two contacts. The interconnect may also include an insulator adhered to the conductor and mechanically supporting the two portions of the conductor. The insulator may include an opening such that the fuse overlaps with this opening, and the opening does not interfere with the operation of the fuse. In some embodiments, the fuse may not directly interface with any other structures. Furthermore, the interconnect may include a temporary substrate adhered to the insulator such that the insulator is disposed between the temporary substrate and the conductor.