Multilayer Flexible Battery Interconnects for High-Current Welding
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Solution Overview
Problem
Conventional battery pack interconnects using rigid metal plates are costly, complex, and prone to failure under stress and vibration, limiting the reliability and efficiency of battery packs, particularly in high-current applications.
Innovation Solution
Multilayered flexible battery interconnects comprising insulating layers and two conductive layers, where one conductive layer is thicker for current-carrying capacity and the other is thinner for easier welding and fusible link integration, providing robust and efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional rigid metal plates are used for battery interconnects, then current-carrying capacity is achieved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The interconnect is divided into multiple functional layers: a flexible substrate layer, a conductive layer for current carrying, and an insulating layer. This segmentation allows each layer to perform its specific function optimally while reducing overall structural complexity compared to traditional rigid metal plates.
Solution Approach 2:
The invention uses a composite structure combining flexible substrate material, conductive material, and insulating material in a multilayered configuration. This composite approach enables the interconnect to simultaneously achieve flexibility, electrical conductivity, and electrical insulation, reducing the need for separate components.
2Reliability
If conventional rigid metal plates with complex designs are used, then electrical connections are established, but manufacturing cost increases
Solution Approach 1:
The invention replaces rigid metal plates with a flexible thin-film structure consisting of a flexible substrate with conductive and insulating layers. This thin-film approach simplifies manufacturing processes, reduces material costs, and maintains reliable electrical connections through the conductive layer.
Solution Approach 2:
The invention replaces traditional mechanical assembly of multiple rigid metal plates with a laminated flexible structure that can be manufactured as a single integrated component. This substitution of mechanical assembly with a fabricated multilayered structure reduces manufacturing complexity and cost.
3Object-affected harmful factors
If special fuses and connector wires are used for plate-to-battery cell connections, then safety protection is provided, but device complexity increases and reliability decreases under stress
Solution Approach 1:
The invention merges the fuse function directly into the interconnect structure by incorporating a fusible link made of the same conductive material as the interconnect layers. This integration eliminates the need for separate fuse components and connector wires, reducing device complexity while maintaining safety protection against over-currents.
Solution Approach 2:
The conductive layer serves multiple functions: it provides electrical connection between battery cells, carries current, and contains a fusible link for over-current protection. This multi-functionality eliminates the need for separate specialized components, reducing overall device complexity.
4Reliability
If multiple freestanding metal plates are used for large battery packs, then electrical connections are established, but assembly complexity increases and manufacturing cost increases
Solution Approach 1:
The interconnect is segmented into functional layers (substrate, conductive, insulating) that can be manufactured separately and then laminated together, enabling efficient manufacturing while maintaining reliable electrical connections. This layered segmentation allows for standardized production of large battery pack interconnects.
Solution Approach 2:
The multilayered composite structure combines flexibility, conductivity, and insulation in a single integrated component that can be easily assembled into large battery packs. This composite design replaces multiple freestanding metal plates, significantly improving assembly efficiency while maintaining connection reliability.
Data Source
AI summary
Provided are multilayered flexible battery interconnects for interconnecting batteries in battery packs and methods of fabricating thereof. A multilayered flexible battery interconnect comprises insulating layers and two conductive layers, stacked together and positioned between the insulating layers. One conductive layer is thicker than the other. The thinner conductive layer comprises flexible tabs for connecting to batteries and, in some examples, comprises voltage sense traces. The smaller thickness of these flexible tabs ensures welding quality and allows using less energy during welding. The battery cell contacts, to which these flexible tabs are welded, can be significantly thicker. Furthermore, the smaller thickness enables fusible link integration into flexible tabs. At the same time, the two conductive layers collectively conduct current within the interconnect, with the thicker layer enhancing the overall current-carrying capacity. The two conductive layers can be welded together to ensure electric connections and mechanical support.