Flexible Busbar Interconnect Circuits for Battery Cell Rerouting

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Solution Overview

Problem

Conventional busbars used in battery packs are inflexible, requiring individual handling and alignment, and do not allow for dynamic re-routing of electrical connections to maintain current flow around failing or failed battery cells, posing safety risks and operational challenges.

Innovation Solution

Multilayered flexible interconnect circuits with a plurality of busbars and interconnecting units that can selectively connect or disconnect based on electrical input, allowing for dynamic re-routing of electrical connections to manage battery cell failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional busbars are used with individual handling and alignment, then manufacturing simplicity is maintained, but flexibility and adaptability are reduced

Engineering Contradiction:

ImproveflexibilityVSAvoidcomplexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The busbar system is divided into multiple modular segments that can be independently positioned and connected. Each segment can be individually handled and aligned, yet collectively provide flexible reconfiguration capabilities. This segmentation allows the system to adapt to different battery cell arrangements while maintaining manageable complexity through standardized connection interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The busbar design incorporates movable and adjustable components that allow dynamic reconfiguration of electrical connections. The busbars can be repositioned, reoriented, or reconnected to adapt to changing battery pack configurations or failed cell scenarios, transforming a static system into a dynamic one that responds to operational needs.

Inventive Principle:

Principle #15Dynamics

2Reliability

If conventional busbars are used without re-routing capability, then device complexity is reduced, but reliability is worsened during battery cell failures

Engineering Contradiction:

ImprovesafetyVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The busbar system incorporates intermediary connection points and switching mechanisms that allow electrical current to be redirected through alternative paths when battery cells fail. These intermediaries act as mediators between the power source and load, providing multiple routing options that enhance safety and reliability without requiring complete system redesign.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system allows dynamic changing of electrical connection parameters such as connection topology, current path, and active busbar configuration in response to battery cell failures. By altering these parameters, the system maintains reliable operation under varying conditions while managing complexity through controlled parameter adjustment rather than physical reconfiguration.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If individual busbars are handled separately during installation, then manufacturing precision is improved for each component, but productivity is reduced

Engineering Contradiction:

Improvealignment precisionVSAvoidinstallation speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Multiple busbar segments and their alignment features are merged into integrated assemblies or modules that maintain precise relative positioning. This combining approach preserves the manufacturing precision of individual components while reducing the number of separate handling operations required during installation, thereby improving productivity through fewer alignment steps and faster assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Alignment features, positioning elements, and connection interfaces are prepared in advance during manufacturing or pre-assembly stages. This preliminary action ensures that when busbars are installed, precise alignment is achieved quickly without requiring complex real-time adjustment procedures, thus maintaining manufacturing precision while significantly improving installation productivity.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250286236A1Multilayered Flexible Interconnect Circuits with Controllably Interconnectable Busbars and Methods for Operating Thereof

Publication Date: 2025.09.11 CELLINK CORP

AI summary

Provided are multilayered flexible interconnect circuits comprising a plurality of busbars and a plurality of interconnecting units. The plurality of busbars comprises a first busbar and a second busbar. Each of the plurality of interconnecting units is connected to a first busbar and a second busbar and separately connected to an interconnecting-unit control line. Each of the plurality of interconnecting units is stacked between and connected to each of a portion of the first busbar and a portion of the second busbar. Each of the plurality of interconnecting units maintains electrical disconnection between the first busbar and the second busbar before receiving an electrical input through the interconnecting-unit control line. Each of the plurality of interconnecting units is configured to electrically connect the first busbar and the second busbar after receiving the electrical input through the interconnecting-unit control line.