Single Conductor Layer Cell-to-Cell Interconnect for EV Power Supply

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Solution Overview

Problem

Electric vehicle power supplies face challenges such as electrical isolation issues, complex connection points, temperature sensitivity, inadequate structural integrity, and uniformity problems, which affect performance and efficiency.

Innovation Solution

A single conductor layer cell-to-cell interconnect system that includes a conductive layer between insulative layers, with interconnects coupled to battery cathodes and anodes, providing improved electrical isolation, visibility, temperature management, and structural reinforcement, and allowing for simpler module connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple conductor layers are used for cell-to-cell interconnect, then electrical connection flexibility is improved, but manufacturing complexity and alignment precision requirements increase

Engineering Contradiction:

Improveelectrical connection flexibilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The conductive interconnect layer is segmented into multiple discrete interconnect elements (first interconnect, second interconnect, third interconnect) that can be independently formed and connected to different battery cells. This segmentation allows for flexible electrical connections while simplifying the manufacturing process by enabling independent formation of each interconnect segment rather than requiring complex multi-layer alignment.

Inventive Principle:

Principle #1Segmentation

2Loss of energy

If conductor thickness is increased to reduce electrical resistance, then current transport efficiency is improved, but structural space and manufacturing complexity increase

Engineering Contradiction:

Improveelectrical resistanceVSAvoidconductor thickness

Core Design Contradiction:

Loss of energyVSLength of stationary object

Solution Approach 1:

Different interconnect elements have different thicknesses optimized for their specific functions: the first interconnect has a first thickness, the second interconnect has a second thickness, and the third interconnect has a third thickness. This local quality approach allows each interconnect to have the precise thickness needed for its electrical resistance requirements without uniformly increasing the thickness of all conductors, thereby reducing overall structural space requirements.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If complex connection points are used to accommodate multiple battery connections, then electrical connectivity is improved, but structural integrity and manufacturing precision decrease

Engineering Contradiction:

Improveelectrical connectivityVSAvoidstructural integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The interconnect elements are arranged in a three-dimensional configuration with vertical stacking (first interconnect above second interconnect, third interconnect positioned at different elevation) rather than planar arrangement. This dimensional approach allows multiple battery connections to be accommodated by distributing connection points across different vertical levels, reducing the complexity of any single connection point while maintaining excellent electrical connectivity and structural integrity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution ensures reliable electrical isolation, consistent battery temperatures, enhanced structural integrity, and improved uniformity, leading to more efficient and reliable power supply operations in electric vehicles.

Implementation Method 1

a conductive interconnect layer carried by the retainer... The conductive interconnect layer includes a conductive layer positioned between first and second insulative layers... The conductive layer includes multiple interconnects configured to be coupled to cathodes and anodes of the batteries

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a terminal bar configured to transport electrical currents to and from the conductive interconnect layer

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

a conductive layer positioned between first and second insulative layers

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS20230048671A1Single conductor layer cell-to-cell interconnect for electric vehicle power supply or other power supply

Publication Date: 2023.02.16 WHS ENERGY SOLUTIONS LLC

AI summary

An apparatus includes an interconnect assembly configured to receive and retain multiple batteries. The interconnect assembly includes a retainer configured to receive portions of the batteries, a conductive interconnect layer carried by the retainer, and a terminal bar configured to transport electrical currents to and from the conductive interconnect layer. The conductive interconnect layer includes a conductive layer positioned between first and second insulative layers, where the conductive layer has a first thickness that is less than a thickness of the terminal bar. The conductive layer includes multiple interconnects configured to be coupled to cathodes and anodes of the batteries.