Battery Interconnect Device Segmented Contact Member Geometry

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Solution Overview

Problem

Existing interconnect devices for battery cell assemblies face challenges in reliably coupling electrodes with different polarities while ensuring equal current flow and minimal air restriction.

Innovation Solution

The interconnect device features electrical contact members with specific geometric configurations, including contact portions, extension portions, and intermediate portions, designed to couple electrodes of varying polarities in a series configuration, constructed from nickel-plated copper or other conductive materials, allowing for welding or other coupling processes, and featuring bending points for forming from metal sheets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing interconnect devices are used to couple battery cells, then electrical connection is achieved, but reliable coupling of electrodes with different polarities and equal current flow is not ensured

Engineering Contradiction:

Improvereliability of electrical connectionVSAvoidcomplexity of contact member configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The contact member is segmented into multiple portions (first contact portion, second contact portion, third contact portion, fourth contact portion) with different geometries, each optimized for specific electrode configurations. This segmentation allows the single contact member to reliably couple electrodes of different polarities while maintaining equal current flow paths.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the contact member have different local geometries and properties - the first and third contact portions are configured for first-polarity electrodes, while the second and fourth contact portions are configured for second-polarity electrodes. This local quality variation ensures reliable electrical connection across all battery cells in the series string.

Inventive Principle:

Principle #3Local quality

2Reliability

If contact members are designed to connect electrodes of different polarities, then electrical connection is achieved, but equal current flow through all cells is not ensured

Engineering Contradiction:

Improveequal current flowVSAvoidmanufacturing of contact members

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The contact member geometry is varied across different portions to control electrical resistance. By adjusting the cross-sectional area, length, and material distribution in each portion, the design ensures equal current flow through all battery cells. The first and third contact portions have different geometries than the second and fourth portions to match different electrode configurations while maintaining balanced current distribution.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The contact member may be constructed from composite materials or plated materials (e.g., copper with tin or nickel plating) to optimize both electrical conductivity and manufacturability. This allows achievement of equal current flow while maintaining ease of manufacturing through standard fabrication processes.

Inventive Principle:

Principle #40Composite materials

3Reliability

If interconnect devices are placed between battery cells, then electrical connection is achieved, but air restriction increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidair restriction

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The contact member is designed with a thin, planar geometry that occupies minimal space in the direction perpendicular to the battery cell surfaces. By extending the contact portions laterally rather than vertically, the design achieves reliable electrical connection while minimizing air restriction and allowing adequate airflow between battery cells for thermal management.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The contact member functions as a thin film or flexible interconnect that can conform to the battery cell surfaces while maintaining electrical contact. This thin-film approach ensures reliable electrical connection with minimal interference to airflow patterns between battery cells.

Inventive Principle:

Principle #30Flexible shells and thin films

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 configuration ensures equal electrical resistance and current flow through the contact members, effectively connecting electrodes of different polarities while allowing for airflow, enhancing the reliability and efficiency of battery cell assemblies.

Implementation Method 1

The interconnect device includes a first electrical contact member having first and second contact portions, a first extension portion, and a first intermediate portion... The first contact portion is configured to contact a first electrode of a first battery cell assembly having a first polarity, and the second contact portion is configured to contact a second electrode of a second battery cell assembly having a second polarity

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP2343756B1Interconnection device for battery cell assemblies

Publication Date: 2014.09.10 LG CHEM LTD

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AI summary

An interconnect device for battery cell assemblies is provided. The interconnect device couples a first set of electrodes at a first polarity in series with a second set of electrodes at a second polarity in a battery module.