Battery Module Interconnect Layout for Low Resistance and Heat Flow

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Solution Overview

Problem

Existing battery module interconnections face challenges in achieving reduced resistance and improved thermal conductivity while maintaining a fusible interconnect to prevent overcurrent conditions.

Innovation Solution

A hybrid interconnection system is employed where terminals of one polarity are coupled to a busbar via bond wires and terminals of opposite polarity are coupled to a collector plate via tabs, utilizing ultrasonic or laser welding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional single-type interconnections are used, then device complexity is reduced, but resistance and thermal conductivity are insufficient

Engineering Contradiction:

Improveresistance and thermal conductivityVSAvoidinterconnection structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The interconnection system is segmented into two distinct types: bond wires for connecting positive terminals to the busbar, and tabs for connecting negative terminals to the collector plate. This segmentation allows each interconnection type to be optimized for its specific function, achieving lower resistance and improved thermal conductivity through specialized design rather than using a single generic interconnection structure for all terminals.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different interconnection structures are applied to different locations: bond wires are used at positive terminals while tabs are used at negative terminals. Each location receives a locally optimized interconnection solution tailored to its specific electrical and thermal requirements, thereby improving overall system performance without requiring complete redesign of all interconnections.

Inventive Principle:

Principle #3Local quality

2Reliability

If hybrid interconnection system is implemented, then resistance decreases and thermal conductivity improves, but device complexity increases

Engineering Contradiction:

Improveelectrical and thermal performanceVSAvoidinterconnection system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges two different interconnection technologies (bond wire and tab) into a single hybrid system that works together to achieve superior electrical and thermal performance. The bond wires and tabs are integrated within the same battery module, with the busbar and collector plate serving as common connection points, thereby combining the advantages of both interconnection types while managing the complexity through unified system architecture.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If conventional interconnections are used, then manufacturing is simpler, but overcurrent protection capability is insufficient

Engineering Contradiction:

Improveovercurrent protectionVSAvoidinterconnection assembly

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fusible interconnect acts as an intermediary safety mechanism between the hybrid interconnection system and the electrochemical cells. This specialized component is designed to melt and interrupt current flow during overcurrent events, providing overcurrent protection while being integrated into the existing bond wire and tab structure. The fusible interconnect adds protective functionality without requiring complete redesign of the manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach decreases resistance and enhances thermal conductivity, while ensuring a fusible interconnect that interrupts electricity flow during overcurrent events.

Implementation Method 1

a busbar and a plurality of bond wires, each of the bond wires coupling the first terminal of a respective one of the electrochemical cells to the busbar

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a collector plate including tabs, each of the tabs coupled to the second terminal of a respective one of the electrochemical cells

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS12381291B2Collector-plate and wire-bond interconnections for battery module

Publication Date: 2025.08.05 ATIEVA INC(US)

AI summary

A battery module comprises: electrochemical cells arranged in rows with terminals in a coplanar arrangement, the electrochemical cells including first and second terminals of opposite polarity at respective first ends of the electrochemical cells; a busbar and a plurality of bond wires, each of the bond wires coupling the first terminal of a respective one of the electrochemical cells to the busbar; and a collector plate including tabs, each of the tabs coupled to the second terminal of a respective one of the electrochemical cells.