Insulation Testing Probe Array for Pouch Cell Modules
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Solution Overview
Problem
Existing methods for checking the insulation of cell module assemblies composed of pouch cells are unreliable and time-consuming, as they rely on point-contact probing which can deform the pouch material and require individual cell measurements, making it difficult to automate and ensuring reliable contact.
Innovation Solution
An apparatus and method using a first probing unit electrically contacted to the electrode and a second probing unit made of conductive elastic material with grooves, allowing contact with multiple pouch cells' aluminum films, along with a measuring and determining means to assess insulation resistance, ensuring reliable and rapid measurement of the entire cell module assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a probing unit is point-contacted with the aluminum film to measure insulation, then the measurement can be performed, but the pouch material is easily deformed and reliable contact cannot be ensured
Solution Approach 1:
The probing unit is divided into multiple contact points arranged in an array, where each contact point can independently contact the aluminum film of different pouch cells. This segmentation allows the measurement force to be distributed across multiple points, reducing the deformation at each individual contact point while maintaining reliable electrical contact for insulation measurement.
Solution Approach 2:
The probing unit incorporates contact points with different local properties - some contact points are designed with larger contact areas to reduce pressure and prevent deformation, while others maintain smaller contact areas for precise electrical connection. This local quality variation allows the system to simultaneously achieve reliable measurement contact and minimize pouch deformation.
2Reliability
If individual pouch cells are measured one by one for insulation, then complete coverage is achieved, but the checking time is excessively long
Solution Approach 1:
Multiple probing units are combined into a single array structure that can simultaneously contact and measure multiple pouch cells. By merging the measurement functions of multiple probes into one integrated apparatus, the system achieves complete insulation checking coverage across all pouch cells in the module while reducing the total measurement time from sequential to parallel operation.
Solution Approach 2:
The probing array is designed as a universal measurement tool that can simultaneously perform insulation measurements on multiple different pouch cells with a single operation. Each probing unit in the array maintains the same measurement function, allowing the system to universally apply the insulation checking process across the entire cell module assembly in parallel.
3Reliability
If force is applied to ensure physical contact between probing unit and aluminum film, then electrical connection is improved, but the pouch outer periphery is easily deformed
Solution Approach 1:
The total contact force required for reliable electrical connection is segmented and distributed across multiple contact points in the array. Instead of concentrating force at a single point which would deform the pouch, the force is divided into multiple smaller forces applied at different locations, each sufficient for electrical contact but too small to cause structural deformation.
Solution Approach 2:
The probing unit incorporates flexible contact elements that can adapt to the surface of the aluminum film without requiring excessive force. These flexible elements maintain reliable electrical contact through elastic deformation of the probe itself rather than through force that would deform the pouch structure, preserving the structural integrity of the pouch while ensuring good electrical connection.
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
This approach allows for rapid and reliable insulation checking of cell module assemblies, reducing time and costs by assessing the entire assembly rather than individual cells, and ensuring stable electric contact to prevent damage to the pouch material.
Implementation Method 1
a second probing means electrically contacted to aluminum films of selected ones of the pouch cells
Data Source
AI summary
An apparatus for checking insulation of a cell module assembly composed of a plurality of pouch cells includes a first probing unit electrically contacted to an electrode of the cell module assembly; a second probing unit electrically contacted to aluminum films of selected ones of the pouch cells in the cell module assembly; and a measuring unit for measuring an insulation resistance between the first probing unit and the second probing unit. This apparatus may measure insulation resistances of a plurality of pouch cells of the cell module assembly at once, thereby ensuring faster insulation checking.