Multilayer Flexible Battery Interconnect Circuit for Simpler Pack Assembly
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Solution Overview
Problem
Conventional busbars used in battery packs are complex to assemble due to individual handling and alignment requirements, lack flexibility, and require additional components like voltage-sense harnesses, complicating the installation process.
Innovation Solution
Multilayered flexible interconnect circuits comprising multiple conductive layers with insulators that allow direct interfacing and welding, eliminating the need for separate handling and alignment of components, and integrating busbars and voltage traces into a single flexible structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional busbars are used for battery interconnection, then current-carrying capacity is achieved, but assembly complexity increases due to individual handling and alignment requirements
Solution Approach 1:
The patent combines multiple busbars and voltage-sense harnesses into a single multilayered flexible interconnect circuit. The circuit integrates high-current conductive paths and low-current sensing paths in different layers, eliminating the need for separate components and simplifying assembly while maintaining current-carrying capacity.
Solution Approach 2:
The invention transitions from planar busbar arrangements to a three-dimensional multilayered structure. Conductive layers are stacked vertically with insulators between them, allowing multiple electrical paths to coexist in the same footprint area, thereby reducing assembly complexity without sacrificing electrical performance.
2Strength
If conventional rigid busbars are used, then structural strength is maintained, but flexibility is reduced
Solution Approach 1:
The patent replaces rigid busbars with flexible thin-film conductive layers deposited on flexible substrates. The multilayered structure with thin insulator and conductor layers provides both mechanical flexibility for adaptation to battery pack contours and sufficient electrical performance for current carrying.
Solution Approach 2:
The invention uses composite material structures combining flexible substrates, conductive metal layers, and insulating layers. This composite approach provides both the flexibility needed for adaptation and the structural integrity required for reliable electrical connection.
3Adaptability or versatility
If multiple separate components are used for battery interconnection, then functional requirements are met, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple functional components (busbars for high current, voltage-sense harnesses for monitoring, and interconnect pathways) into a single multilayered flexible circuit. This consolidation reduces the number of separate manufacturing steps and assembly operations required.
Solution Approach 2:
The multilayered flexible interconnect circuit serves multiple functions simultaneously: high-current transmission, low-current sensing, and electrical interconnection. Different layers perform different functions, allowing a single component to replace multiple specialized components.
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
Simplifies battery pack assembly by integrating busbars and voltage traces, enhances flexibility, and reduces operational complexity while maintaining high current-carrying capacity and low-current sensing capabilities.
Implementation Method 1
both are welded to the cell terminals of two adjacent battery cells
Implementation Method 2
the inner insulator layer is stacked between and directly interfaces the first conductive layer and the second conductive layer
Data Source
AI summary
Provided are multilayered flexible interconnect circuits comprising multiple conductive layers. Also provided are methods of fabricating such circuits and also methods of fabricating battery assemblies with such circuits. A multilayered flexible interconnect circuit comprises at least two conductive layers and at least one inner insulator, which extends between these conductive layers in some circuit portions and allows for conductive layers to directly interface in other circuit portions (e.g., busbar portions). Outer insulators can be provided to insulate these conductive layers from the environment while allowing some access to these layers as needed. Each conductive layer and insulator can be individually patterned to achieve these functions. One or more insulators support conductive layers relative to each other as well as different portions (e.g., disjoined portions) of the same conductive layer. The same multilayered flexible interconnect circuit can provide battery interconnect, voltage/temperature sense, and/or other functions.