Spring Contact Battery Interconnection for Impedance and Thermal Management
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Solution Overview
Problem
Conventional methods for integrating multiple lithium-ion battery cells into a pack face challenges such as inconsistent impedance, overheating, and increased complexity due to poor thermal transfer and varying cell dimensions, which affect even current and heat flow, and require costly tooling and manufacturing processes.
Innovation Solution
A battery packaging apparatus with integrated spring contacts and a battery management system that uses a flexible PCB with electrically conductive traces and a planar conduction medium, where the electric coupling is maintained by friction, allowing for efficient electrical and thermal conductivity while accommodating cell size variations without the need for expensive tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to integrate multiple lithium-ion battery cells into a pack, then the battery pack can be assembled, but inconsistent impedance, overheating, and increased complexity occur due to poor thermal transfer and varying cell dimensions
Solution Approach 1:
The battery pack is divided into modular units with standardized interfaces. Each module contains battery cells arranged in consistent configurations with standardized mounting structures, allowing for consistent impedance characteristics while simplifying overall assembly through repetition of proven designs.
Solution Approach 2:
Standardized interconnection members and mounting structures serve multiple functions simultaneously: electrical connection, mechanical support, thermal management interface, and positioning. This multi-functionality reduces overall system complexity while ensuring consistent electrical and thermal performance across all cell connections.
2Reliability
If conventional interconnection methods are used, then battery cells can be connected, but overheating occurs due to poor thermal transfer
Solution Approach 1:
The interconnection member integrates electrical conduction and thermal conduction functions into a single component. The same conductive material that connects cells electrically also serves as a thermal pathway, ensuring that heat generated during charging/discharging is efficiently transferred away from the cells alongside the electrical current.
Solution Approach 2:
The interconnection member uses composite material structures that optimize both electrical conductivity and thermal conductivity. Materials are selected and configured to provide dual functionality, ensuring efficient heat transfer while maintaining low electrical resistance for reliable power delivery.
3Ease of manufacture
If conventional manufacturing processes are used, then battery packs can be produced, but costly tooling and manufacturing processes are required
Solution Approach 1:
The spring-like elements provide dynamic mechanical force that automatically compensates for variations in cell dimensions. This eliminates the need for precision tooling and complex adjustment mechanisms during assembly, as the spring force naturally ensures consistent contact pressure and electrical connection across all cells regardless of minor size variations.
Solution Approach 2:
The spring-like interconnection members self-adjust to accommodate cell dimension variations without external intervention. The elastic properties of the springs automatically maintain optimal contact force, eliminating the need for costly precision tooling, alignment fixtures, or complex assembly procedures.
4Reliability
If rigid interconnection methods are used, then stable electrical connection can be achieved, but variations in cell dimensions cause inconsistent contact and impedance
Solution Approach 1:
The spring-like interconnection members transform rigid electrical connections into dynamic, adaptive connections. The elastic deformation of the springs allows the system to accommodate cell dimension variations while maintaining consistent contact force and electrical conductivity, ensuring reliable performance across all cells in the pack.
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 solution enables effective monitoring of cell charge states, ensures even current and heat distribution, and simplifies the assembly process by eliminating the need for wires and reducing manufacturing costs, while maintaining reliable electrical connections and thermal management.
Implementation Method 1
a first spring-like element that is coupled to the first face of the electrically conductive element. The spring-like element is operable for providing a force on the electrically conductive element when the first area is translocated toward the second area
Implementation Method 2
the electric coupling between the first planar conduction medium and the electrically conductive trace is maintained by friction between the first planar conduction medium and a substantially parallel nonconductive surface
Implementation Method 3
Charging and discharging of electric batteries may generate heat
Data Source
AI summary
The present disclosure is directed toward apparatuses for packaging one or more cells in a larger battery pack, and apparatuses for electrically coupling a battery management system to the one or more cells in a battery pack. In the aspect of the present disclosure directed toward a battery packaging apparatus with integrated spring contacts, an electrically conductive element has first and second surface a, with the first surface electrically coupled to a first battery, and a first spring-like element that is coupled to the first face of the electrically conductive element. The electrically conductive element has a cross section such that the second surface contacts the spring-like element in first and second areas. The spring-like element is operable for providing a force on the electrically conductive element when the first area is translocated toward the second area.