Battery Module Interconnect Assembly Blade Isolation
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Solution Overview
Problem
Existing battery module designs face challenges in effectively isolating electrical terminals to prevent electrical discharges across air gaps, which can lead to inefficiencies and potential damage.
Innovation Solution
The battery module incorporates interconnect assemblies with plate, finger, and blade portions, along with voltage sense members, where the blade portion electrically isolates the first electrical terminal from the second, using a laser welding method to couple the terminals to the voltage sense members, thereby preventing electrical discharges across air gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical terminals are positioned close to each other in existing battery module designs, then space utilization is improved, but electrical discharges across air gaps can occur leading to inefficiencies and potential damage
Solution Approach 1:
The interconnect assembly is segmented into distinct functional portions: a plate portion for mechanical support, finger portions for electrical connection, and blade portions for electrical isolation. This segmentation allows close positioning of terminals while maintaining isolation through the blade portion that extends between them.
Solution Approach 2:
The blade portion acts as an intermediary element positioned between adjacent electrical terminals. It provides electrical isolation by extending through gaps between terminals, preventing discharge while allowing the terminals to be positioned close together for compact design.
2Ease of manufacture
If traditional welding methods are used to couple terminals to voltage sense members, then manufacturing process is simpler, but coupling precision and reliability may be insufficient
Solution Approach 1:
Traditional mechanical or resistance welding methods are replaced with laser welding technology. The laser welding system provides precise energy delivery to create strong, accurate bonds between electrical terminals and voltage sense members, improving both coupling precision and reliability while maintaining manufacturing efficiency.
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 design effectively isolates electrical terminals, preventing electrical discharges and enhancing the reliability and efficiency of the battery module by ensuring secure and efficient coupling of terminals to voltage sense members.
Implementation Method 1
using a laser welding method to couple the terminals to the voltage sense members
Data Source
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AI summary
A battery module and a method are provided. The battery module includes a first battery cell having a first electrical terminal, a second battery cell having a second electrical terminal, and an interconnect assembly having a plate portion, first and second finger portions, a blade portion, and first and second voltage sense members. The first and second voltage sense members are coupled to the first and second finger portions, respectively. The blade portion is disposed between the first and second finger portions such that a first gap is defined between the first finger portion and the blade portion, and a second gap is defined between the second finger portion and the blade portion. The first and second electrical terminals extend through the first and second gaps, respectively, and are coupled to the first and second voltage sense members, respectively.