Battery Module Interconnect Pad Structure for Short-Circuit Isolation
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Solution Overview
Problem
Existing battery module designs face reliability issues due to the risk of short circuits between flexible interconnects and busbars, caused by mechanical damage from sharp edges or rough surfaces on the busbars.
Innovation Solution
A non-flat conductive pad is used to create a distance between the busbar and the flexible interconnect, enhancing isolation and reducing the risk of short circuits. The pad has a specific shape with multiple parts that provide spacing and flexibility, allowing for improved stress absorption and assembly precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flat pad is used to connect the flexible interconnect to the busbar, then the assembly is simple and direct, but the risk of short circuits increases due to mechanical damage from sharp edges or rough surfaces on the busbar
Solution Approach 1:
The pad structure transitions from a two-dimensional flat configuration to a three-dimensional elevated configuration. The pad is raised above the busbar surface by a height of 0.5-5mm, creating vertical separation that eliminates contact between the flexible interconnect and potential sharp edges or rough surfaces on the busbar, thereby preventing mechanical damage and short circuits.
Solution Approach 2:
The elevated pad acts as an intermediary element between the flexible interconnect and the busbar. By positioning the pad at a height above the busbar surface, it mediates the connection while preventing direct contact between the interconnect and the busbar's potentially harmful surfaces, thus protecting against mechanical damage.
2Volume of moving object
If the flexible interconnect is placed close to the busbar for compact design, then the space utilization is improved, but mechanical damage from sharp edges or rough surfaces on the busbar becomes more likely
Solution Approach 1:
The solution resolves the space conflict by utilizing the vertical dimension rather than increasing horizontal distance. The pad is elevated by 0.5-5mm above the busbar surface, maintaining compact horizontal footprint while creating sufficient vertical clearance to prevent mechanical damage from sharp edges or rough surfaces.
3Manufacturing precision
If manual assembly is used to ensure precise placement of the flexible interconnect, then the assembly precision is improved, but the productivity decreases
Solution Approach 1:
The pad structure is pre-configured with a specific elevated geometry (height of 0.5-5mm) before assembly. This preliminary structural preparation enables automated placement systems to accurately position the flexible interconnect on the elevated pad without requiring complex manual alignment procedures, thus maintaining precision while enabling automation.
Data Source
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AI summary
The present disclosure refers to a battery module and an interconnecting structure, wherein a conductive pad (20) is provided between a flexible interconnect (10) and a busbar (30), and wherein the conductive pad (20) includes a first part (21) extending in a first plane, at least one second part (22) extending in a second plane parallel to the first plane and spaced apart from the first part (21) in a direction perpendicular to the first and second planes, at least one third part (23) connecting the first part (21) with each of the at least one second part (22), the busbar (30) is attached to the first part (21) of the conductive pad (20), and the flexible interconnect (10) is attached to the at least one second part (22) of the conductive pad (20).