Battery Interconnect Device with Integrated Conductive Traces
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Solution Overview
Problem
Conventional interconnect devices for battery assemblies are complex, requiring multiple manufacturing processes and non-standard welds, and their thermistor signal interfaces are prone to damage during assembly due to lack of enclosure.
Innovation Solution
An interconnect device with a non-conductive frame, integrally formed conductive traces, a busbar, and a conductive pad that encloses a substantial portion of the thermistor signal interface, simplifying assembly and providing mechanical support to battery cell terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional interconnect devices use multiple separate components (plastic frame, circuit board, copper busbar), then electrical connection functionality is achieved, but device complexity and manufacturing process complexity increase
Solution Approach 1:
The patent combines the plastic frame, circuit board, and copper busbar into a single integrated interconnect device. The frame includes integrally formed conductive traces and busbars that are molded as one piece, eliminating the need for separate components and reducing assembly steps while maintaining electrical connection functionality.
Solution Approach 2:
The interconnect device uses composite construction with a plastic frame containing integrally formed conductive elements. The frame is made of a non-conductive plastic material with conductive traces and busbars formed within it, creating a composite structure that combines electrical conductivity with mechanical support in a single component.
2Strength
If conventional interconnect devices require side and top welds using non-standard weld tips, then secure attachment to battery assembly is achieved, but manufacturing complexity and alignment difficulty increase
Solution Approach 1:
The interconnect device is designed to work with standard welding equipment and processes. The frame includes features that accommodate standard weld tips, allowing the device to be securely attached to the battery assembly using conventional welding methods without requiring specialized or non-standard weld tips.
3Reliability
If conventional interconnect devices have unenclosed thermistor signal interface, then electrical interface functionality is achieved, but susceptibility to damage during assembly increases
Solution Approach 1:
The thermistor signal interface is nested within the frame structure. The frame includes an enclosed space or recess that houses the thermistor signal interface, protecting it from damage during assembly while maintaining its electrical connection functionality. The interface is integrated into the frame's internal geometry.
4Manufacturing precision
If conventional interconnect devices require three degrees of freedom for alignment, then precise positioning is achieved, but alignment process complexity increases
Solution Approach 1:
The frame includes asymmetric alignment features such as positioning protrusions or asymmetric geometric elements that guide the interconnect device into proper alignment with the battery assembly. These asymmetric features naturally constrain the positioning to the correct orientation, reducing the alignment process complexity while maintaining manufacturing precision.
Data Source
AI summary
An interconnect device for a battery assembly having a plurality of battery cell assemblies and a thermistor is disclosed. The interconnect device includes a non-conductive frame; a plurality of conductive traces integrally formed with the frame, a busbar in electrical communication with at least one of the conductive traces and disposed adjacent an aperture formed in the frame, wherein the aperture receives a tab of at least one of the battery cell assemblies, and a conductive pad disposed on a lower surface of the frame, the pad in electrical communication with at least one of the conductive traces and adapted to receive a signal from the thermistor.