Substrate Integrating Power and Sensing Lines for Battery Systems
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Solution Overview
Problem
The increasing number of interconnected electrochemical cells in power systems leads to increased size, weight, complexity, and maintenance challenges, with wires becoming a source of failure and hindering effective monitoring of cell characteristics.
Innovation Solution
A flexible circuit board with immobilized electrical conductors, including power lines, sensing lines, and interconnects, is attached to the terminals of multiple power sources, providing series and parallel connections while reducing the number of parts and connections, allowing for efficient monitoring and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of interconnected electrochemical cells is increased to meet power demands, then the power output is improved, but the size, weight, and complexity of the system increases
Solution Approach 1:
The patent combines multiple electrical connections (series and parallel interconnects) and monitoring functions into a single substrate structure. This merging of functions reduces the overall system complexity while maintaining the ability to handle large numbers of electrochemical cells for high power output requirements.
Solution Approach 2:
The substrate serves multiple functions simultaneously: it provides mechanical support, electrical interconnection (both series and parallel), and monitoring capabilities. This multi-functionality reduces the number of separate components needed, thereby reducing system complexity while supporting scalable power configurations.
2Power
If the number of interconnected electrochemical cells is increased, then the power output is improved, but the weight of the system increases
Solution Approach 1:
By combining multiple electrical connections and monitoring elements into a single substrate, the patent reduces the total amount of wiring and supporting structures needed. This integration reduces the overall weight of the system while maintaining the capability to connect large numbers of cells for high power output.
3Power
If the number of interconnected electrochemical cells is increased, then the power output is improved, but the number of wires and connections increases
Solution Approach 1:
The patent merges multiple separate wire connections into integrated circuit traces on a substrate. This consolidation dramatically reduces the number of discrete connections while maintaining all necessary electrical pathways for series and parallel configurations of electrochemical cells.
Solution Approach 2:
The patent replaces mechanical wire connections with printed circuit board traces. This substitution eliminates the need for numerous physical wire connections and manual assembly steps, reducing connection complexity while supporting scalable power configurations.
4Reliability
If wires are used to connect electrochemical cells, then electrical communication is provided, but reliability decreases due to wire-related failures
Solution Approach 1:
The patent replaces mechanical wire connections with rigid or flexible printed circuit board traces. This substitution eliminates connection points that are prone to failure from vibration, thermal cycling, and manual assembly errors, thereby improving reliability while reducing connection complexity.
Solution Approach 2:
By combining multiple electrical connections into a single integrated substrate structure, the patent reduces the number of potential failure points. Fewer discrete connections mean fewer opportunities for connection failures, improving overall system reliability.
Data Source
AI summary
A substrate is physically attached to the terminals of multiple different power sources. The substrate includes multiple electrical conductors. Each of the electrical conductors is immobilized along its length relative to the substrate. The electrical conductors include interconnect lines and sensing lines. The interconnect lines provide electrical communication between the power sources. At least one of the sensing lines carries an electrical signal indicating a voltage across one or more of the power sources. Electronics that are immobilized on the substrate employ the electrical signal to determine the voltage across the one or more power sources.