Battery Cell Interconnect Panels for Simpler Module Assembly
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Solution Overview
Problem
Conventional battery modules are difficult to manufacture and require complex procedures and specialized machinery, necessitating a simpler and less expensive interconnect system for battery cells.
Innovation Solution
A battery module design featuring upper and lower interconnect panels made of conductive metal, a carrier with a lead frame molded into thermoplastic resin, and a monitoring module to facilitate easier assembly and monitoring of electrical properties, allowing for efficient connection and circuit arrangement of battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery module construction is used, then battery cells can be connected in parallel and/or series with individual fusing, but the manufacturing process becomes complicated and requires specialized machinery
Solution Approach 1:
The patent combines multiple functions into a single integrated interconnect system. The interconnect structure merges electrical connection, fusing protection, and monitoring capabilities into one unified component that attaches to battery cell terminals, eliminating the need for separate fusing devices and complex assembly procedures while maintaining safety and reliability functions
Solution Approach 2:
The interconnect structure serves multiple functions simultaneously: it provides electrical connection between cells, acts as a fuse for protection, supports monitoring electrodes, and enables both series and parallel circuit configurations. This multi-functionality reduces manufacturing complexity by eliminating the need for separate specialized components for each function
2Reliability
If battery cells are arranged closely together with individual fusing, then safety and protection are improved, but the manufacturing procedure becomes more complex
Solution Approach 1:
The interconnect structure merges the fusing function directly into the electrical connection component. The interconnect itself acts as a fuse with a defined failure mode that protects adjacent cells, eliminating the need for separate fusing devices and reducing overall system complexity while maintaining safety protection
3Productivity
If conventional interconnect systems are used, then battery cells can be connected, but the manufacturing process requires specialized machinery and complicated procedures
Solution Approach 1:
The interconnect structure is pre-formed with integrated fusing elements, monitoring electrode attachments, and connection geometries before assembly. This preliminary preparation allows for simplified assembly processes where the pre-configured interconnect is simply attached to battery cell terminals, reducing the need for specialized machinery during final assembly
Solution Approach 2:
The patent integrates monitoring electrode attachments directly onto the interconnect structure, combining the interconnection and monitoring functions into a single assembly step. This merging of functions simplifies manufacturing by eliminating separate operations for installing monitoring devices
Data Source
AI summary
A battery module having a plurality of battery cells disposed in a housing and interconnected by upper and lower interconnect panels stamped from sheets of conductive metal. Each of the upper and lower interconnect panels have a plurality of contacts secured to terminals of the battery cells, respectively. The contacts are at least partially disposed in panel openings extending through the upper and lower interconnect panels. A carrier is provided and includes a lead frame molded into a body of thermoplastic resin. The lead frame connects a plurality of locations on the upper and lower interconnect panels to a monitoring module that measures physical properties at the locations.