Integrated Battery Power Bus Substrate for Low-Connection Pack Assembly

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Solution Overview

Problem

Conventional battery packs are mass- and volume-inefficient due to separate power buses and numerous wire/bus bar connections, leading to increased cost, complexity, and safety issues, as well as inefficiencies in heat management and noise interference.

Innovation Solution

Integration of a power bus with the battery management system (BMS) unit, where the power bus is embedded into a substrate, eliminating the need for wires and bus bar connections, and using direct physical connections between the substrate and electrochemical cells for heat and power transfer, along with a controller for efficient management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If separate power buses and wire/bus bar connections are used, then power transfer is achieved, but mass and volume efficiency deteriorate

Engineering Contradiction:

Improvepower transfer efficiencyVSAvoidbattery pack mass

Core Design Contradiction:

Loss of energyVSWeight of stationary object

Solution Approach 1:

The patent merges the power bus with the substrate by integrating conductive traces directly into the substrate structure. This eliminates separate power buses and wire connections, reducing mass while maintaining power transfer functionality. The substrate itself becomes the power distribution network, achieving both power transfer efficiency and mass reduction.

Inventive Principle:

Principle #5Merging (Combining)

2Loss of energy

If separate power buses and numerous wire/bus bar connections are used, then power transfer is achieved, but device complexity increases

Engineering Contradiction:

Improvepower transfer efficiencyVSAvoidconnection complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The power bus is merged with the substrate, eliminating numerous separate wire and bus bar connections. The integrated conductive traces on the substrate provide power distribution pathways, significantly reducing connection complexity while maintaining effective power transfer to electrochemical cells.

Inventive Principle:

Principle #5Merging (Combining)

3Power

If numerous wire/bus bar connections are used, then power distribution is achieved, but safety deteriorates

Engineering Contradiction:

Improvepower distribution capabilityVSAvoidsystem safety

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

By integrating the power bus into the substrate, the patent eliminates numerous separate connections that could fail or create safety hazards. The unified substrate structure with embedded conductive traces provides more reliable and safer power distribution, reducing connection points where failures could occur.

Inventive Principle:

Principle #5Merging (Combining)

4Power

If separate power buses are used, then power transfer is achieved, but thermal management efficiency deteriorates

Engineering Contradiction:

Improvepower transfer capabilityVSAvoidheat management efficiency

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The integration of the power bus with the substrate creates a unified structure that simultaneously handles both power transfer and heat dissipation. The conductive traces in the substrate serve dual functions: distributing power to cells and conducting heat away from them, improving thermal management efficiency while maintaining power transfer capability.

Inventive Principle:

Principle #5Merging (Combining)

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 approach results in a more efficient, safer, and cost-effective battery pack with reduced connection points, improved thermal management, and enhanced power efficiency, making it suitable for applications like aerial vehicles.

Implementation Method 1

a substrate directly connected to the at least one electrochemical cell and configured to transfer heat, power, and signals between the substrate and the at least one electrochemical cell

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a substrate directly connected to the at least one electrochemical cell and configured to transfer heat, power, and signals between the substrate and the at least one electrochemical cell

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20250007014A1Systems and methods for providing, assembling, and managing integrated power bus for rechargeable electrochemical cell or battery

Publication Date: 2025.01.02 SION POWER CORP

AI summary

A battery pack comprising a substrate comprising a battery power bus integrated into the substrate; and a pack controller; and at least one electrochemical cell connected directly to the substrate. A printed circuit board comprising a power bus integrated into the printed circuit board, wherein the power bus is connected to and configured to transfer power to and/or from at least one electrochemical cell; and at least one controller configured to control the at least one electrochemical cell. A thermal management system comprising at least one electrochemical cell; and a substrate directly connected to the at least one electrochemical cell and configured to transfer heat, power, and signals between the substrate and the at least one electrochemical cell. A thermal management method. A method of assembling a battery pack, comprising attaching at least one electrochemical cell of the battery pack directly to a substrate at least in part by welding.