Battery Interconnect Assembly for Harness-Free Cell Sensing
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Solution Overview
Problem
Existing battery interconnect systems are time-consuming and prone to variability in manufacturing, and rely on unreliable wire harnesses for voltage sensing, temperature sensing, and cell balancing, leading to reduced reliability and longevity.
Innovation Solution
An interconnect assembly with conductive layers and tabs that connect to cell terminals, providing a structured and efficient method for electrical connections, sensing, and cell balancing, eliminating the need for wire harnesses and improving manufacturing consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or soldering wires to cell terminals is used for interconnecting cells, then electrical connections can be achieved, but manufacturing time increases and variability is introduced
Solution Approach 1:
The patent combines multiple separate components (wire harnesses, individual connectors, sensing elements) into a single integrated interconnect assembly that performs all functions simultaneously. This merging eliminates the need for multiple separate welding/soldering operations while maintaining reliable electrical connections, thus resolving the contradiction between connection reliability and manufacturing speed.
Solution Approach 2:
The interconnect assembly is pre-assembled with all electrical connections, sensing elements, and balancing circuits configured before installation. This preliminary preparation allows the entire assembly to be installed as one unit rather than requiring multiple separate connection operations during battery pack assembly, thereby improving manufacturing productivity without sacrificing connection reliability.
2Adaptability or versatility
If wire harnesses are used for voltage sensing, temperature sensing, and cell balancing, then these functions can be performed, but reliability decreases and failure points increase
Solution Approach 1:
The patent integrates voltage sensing, temperature sensing, and cell balancing functions into the same interconnect assembly that provides electrical connections. By combining power transmission and sensing functions into a single integrated structure with fewer connection points, the system maintains full adaptability for all sensing and balancing capabilities while eliminating the reliability issues associated with separate wire harnesses.
Solution Approach 2:
The interconnect assembly serves multiple functions simultaneously: it provides electrical connections for power transmission, incorporates voltage sensing capabilities, includes temperature sensing elements, and enables cell balancing operations. This multi-functionality in a single integrated component eliminates the need for separate wire harnesses for each function, thereby maintaining system versatility while improving overall reliability by reducing the number of potential failure points.
Data Source
AI summary
Exemplary systems and methods enable efficient and reliable positioning, assembly, retention, interconnection, and management of battery cells in battery packs, for example battery packs utilized in electric vehicles.