Hybrid Battery Interconnects for Stronger Dissimilar-Tab Welds
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Solution Overview
Problem
Existing battery submodule designs face challenges in creating robust connections between interconnects and battery cell tabs made of dissimilar metals, leading to potential failure, especially in mission-critical applications like aerial vehicles due to suboptimal weld quality.
Innovation Solution
The use of hybrid interconnects with two portions made of different metals or treated to have distinct physical and chemical properties, allowing for stronger welds with both aluminum and copper tabs, enhancing the connection robustness and electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-metal interconnect is used to connect to dissimilar metal tabs, then the device complexity is reduced, but the connection strength and weld quality deteriorate
Solution Approach 1:
The interconnect is divided into two distinct portions: a first portion made of a first metal adapted to connect to tabs of the first metal, and a second portion made of a second metal adapted to connect to tabs of the second metal. This segmentation allows each portion to be optimally matched to its corresponding tab material, resolving the weld quality issue while maintaining manageable device complexity through a modular two-part structure.
Solution Approach 2:
The interconnect employs a composite structure combining two different metals in a single component. The first metal portion and second metal portion are joined together to form a hybrid interconnect that leverages the advantageous properties of each metal for its specific connection task, thereby achieving superior overall performance compared to single-metal alternatives.
2Strength
If a hybrid interconnect with two different metals is used, then the connection strength improves, but the manufacturing complexity increases
Solution Approach 1:
By segmenting the interconnect into two separate metal portions that can be manufactured independently using standard processes for each metal type, the manufacturing complexity is managed. Each portion can be produced using optimized processes for its specific metal, then joined together, making the overall manufacturing more manageable despite the hybrid nature of the final component.
Solution Approach 2:
The invention allows for parameter changes in the interconnect structure by varying the metal composition, dimensions, and physical properties of each portion based on specific application requirements. This flexibility enables optimization of both connection strength and manufacturing ease by adjusting parameters such as metal selection, portion thickness, and joining methods to match production capabilities.
3Productivity
If dissimilar metal connections are made with traditional methods, then the production process is simple, but the reliability of battery submodule fails
Solution Approach 1:
The segmented hybrid interconnect design maintains production efficiency by allowing each metal portion to be manufactured and prepared separately using streamlined processes, then assembled through reliable joining methods. This segmentation prevents the reliability issues of dissimilar metal connections by ensuring each interface is optimized for its specific metal pairing, while the modular approach keeps the overall production process efficient and scalable.
Solution Approach 2:
The composite hybrid interconnect structure improves battery submodule reliability by eliminating weak welds between dissimilar metals. Each metal portion is specifically selected and designed to create strong, reliable connections with its corresponding tab material, thereby preventing connection failures and enhancing overall system reliability without significantly complicating the production process.
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
The hybrid interconnects provide improved strength and electrical reliability between dissimilar metal tabs, reducing the risk of connection failure and ensuring the stability of battery submodules in critical applications.
Implementation Method 1
The hybrid interconnect includes a first portion and a second portion having different physical properties than the first portion
Data Source
AI summary
The embodiments describe a system and the corresponding assembly techniques of a battery submodule top cover. The battery submodule top cover has at least one electrical hybrid interconnect coupled to a substrate. The hybrid interconnect comprises at least a first portion made of a first metal type, and a second portion made of a second metal type. The first portion and the second portion of the hybrid interconnect are joined together such that an electrical connection may be made between two battery cell tabs where each battery cell tab is made of a different type of metal.