Battery Module Transformer Communication Link Sealing

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Solution Overview

Problem

Wired data communication between mechanically enclosed or housed subsystems in electric vehicles is challenging due to the need for breaking mechanical isolation, which requires piercing and sealing techniques, complicating the process.

Innovation Solution

The implementation of transformers with coils inside module enclosures that engage to form communication links without the need for wire holes, allowing data communication between battery modules housed in adjacent enclosures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If wired data communication is implemented between mechanically enclosed battery modules, then data communication capability is improved, but mechanical integrity of enclosures deteriorates due to required piercing and sealing techniques

Engineering Contradiction:

Improvedata communication capabilityVSAvoidmechanical integrity of enclosures

Core Design Contradiction:

Loss of informationVSStrength

Solution Approach 1:

The patent replaces the mechanical wired communication system with an electromagnetic field-based wireless communication system. Transformers (T1, T2) are used to establish inductive coupling between adjacent battery modules, enabling data communication through electromagnetic induction without any physical penetration of the enclosure walls. This substitution eliminates the need for piercing techniques while maintaining communication capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces transformers as intermediary devices that facilitate data communication between isolated enclosures. The transformers act as magnetic field mediators, allowing signal transmission through the air gap between enclosures without direct physical contact or penetration, thus preserving the mechanical integrity of both enclosures while enabling communication.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of information

If piercing techniques are used to create wire holes for communication, then data communication is enabled, but device complexity increases due to sealing requirements

Engineering Contradiction:

Improvedata communication capabilityVSAvoidsealing and piercing complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The patent eliminates the entire mechanical piercing and sealing subsystem by replacing it with an electromagnetic field-based communication system. The transformers enable inductive coupling through the enclosure walls without requiring any holes, seals, or piercing mechanisms, thereby dramatically reducing device complexity while maintaining communication functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of information

If wire holes are created in enclosures for communication links, then data communication between modules is improved, but reliability deteriorates due to potential vulnerabilities at piercing points

Engineering Contradiction:

Improvedata communication capabilityVSAvoidenclosure sealing reliability

Core Design Contradiction:

Loss of informationVSReliability

Solution Approach 1:

The patent replaces the vulnerable mechanical piercing points with a contactless electromagnetic field-based communication system. The transformers create magnetic coupling through the intact enclosure walls, eliminating all potential failure points associated with holes, seals, and piercing mechanisms, thereby significantly improving system reliability while maintaining communication capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enables secure and efficient data communication between battery modules while maintaining the mechanical integrity of the enclosures, reducing the complexity and potential vulnerabilities associated with piercing the enclosures.

Implementation Method 1

a first coil proximate to and inside of the first housing, and a second coil proximate to and inside of the second housing, wherein the first coil forms a primary winding of a transformer and the second coil forms a secondary winding of the transformer

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10538170B2Battery module communication link connection with improved sealing

Publication Date: 2020.01.21 FARADAY&FUTURE INC

AI summary

Battery module communication system with improved enclosure sealing is disclosed. When applied to an electric vehicle, a battery data communication system disclosed herein includes module enclosures having partial transformers, such as coils, contained inside the enclosures having inter-module interfaces. The inter-module interfaces can engage with one another to form transformers without the module enclosures having wire holes to connect data communication circuits contained in the respective module enclosures.