Curved Interconnect Assembly for Battery Packs Under Thermal and Mechanical Stress
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Solution Overview
Problem
Existing interconnects for electrochemical cells and modular battery packs are prone to breakage or disconnection under extreme thermal and mechanical stresses, such as those encountered in harsh environments like oil and gas drilling operations, where temperatures exceed 150°C and mechanical vibrations are significant, compromising electrical power delivery.
Innovation Solution
A robust interconnect assembly with a curved, braided metal structure that provides flexibility and structural integrity, featuring a 'C' or 'S' shape and interwoven strands, which reduces mechanical stress concentration and enhances durability, allowing it to withstand extreme temperatures and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional folded metal tabs are used to connect electrochemical cells, then the interconnect structure is simple and easy to manufacture, but the interconnect is prone to breakage and disconnection under extreme thermal and mechanical stresses
Solution Approach 1:
The interconnect body is formed with a curved configuration (C-shape or S-shape) rather than straight folds, allowing it to flex and absorb mechanical stresses from vibration and thermal expansion without breaking. The curved geometry distributes stress along the arc, preventing stress concentration at sharp fold points that cause traditional accordion-style tabs to fail.
Solution Approach 2:
The interconnect assembly combines multiple materials: a metal body (nickel, stainless steel, or copper alloy) for electrical conductivity and structural strength, with an epoxy resin coating for environmental protection and additional mechanical reinforcement. This composite structure provides both electrical functionality and resistance to harsh thermal and chemical environments.
2Reliability
If the interconnect is positioned external to the electrochemical cell, then it provides a conduit for electrical energy, but it has increased exposure to thermal and mechanical stresses making it prone to breakage
Solution Approach 1:
The interconnect body incorporates built-in flexibility and stress-absorbing geometry (curved configurations) that anticipate and cushion against upcoming mechanical shocks and thermal expansions. The curved design acts as a shock absorber, flexing to accommodate cell expansion during charging cycles and damping vibration forces before they can cause failure.
Solution Approach 2:
The flexible interconnect body acts as an intermediary element between the rigid electrochemical cells, absorbing and mediating the thermal and mechanical stresses that would otherwise be transmitted directly between cells. Its curved geometry and material properties allow it to decouple the mechanical connection while maintaining electrical continuity.
3Adaptability or versatility
If the interconnect uses multiple folds in an accordion-like fashion, then it provides mechanical resilience as cells are spaced apart, but it is susceptible to shear and breakage along the folds under extreme vibration and temperature
Solution Approach 1:
The interconnect transitions from sharp angular folds to smooth curved configurations. The C-shape or S-shape geometry distributes mechanical stress along the curved path rather than concentrating it at fold points, maintaining flexibility while eliminating the weak points where shear failure occurs in traditional accordion folds.
Solution Approach 2:
The interconnect geometry is changed from linear folds to curved configurations, fundamentally altering how mechanical stresses are distributed. The curved parameters (radius of curvature, arc length) are optimized to provide both flexibility and strength, changing the stress distribution pattern from concentrated at folds to distributed along the curve.
Data Source
AI summary
Various embodiments of an electrochemical cell interconnect assembly are described. The interconnect assembly is designed to be positioned between two adjacent electrochemical cells, providing an electrical conduit therebetween. The interconnect assembly consists of an interconnect body having a curved formed and an interwoven wire structure. The interconnect assembly is designed to provide a robust electrical connection between two adjacent electrochemical cells in extreme mechanical stress and temperature environments.