Balancing Circuit Board for Energy Storage Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ultra-capacitor (UC) modules face cell voltage unbalance issues during charge, standby, or discharge, leading to accelerated cell aging and potential damage due to overvoltage, and require complex connections with harnesses and connectors that increase manufacturing costs and risk of errors.
Innovation Solution
An energy storage device module with a balancing circuit board that can be directly electrically connected to both positive and negative terminals without harnesses or connectors, featuring a cutout structure to reduce stress and using elastic members for support, allowing for efficient cell balancing and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If harnesses and connectors are used to electrically connect balancing circuit boards to energy storage devices, then electrical connectivity is achieved, but manufacturing cost increases and connection errors may occur
Solution Approach 1:
The balancing circuit board is integrated directly with the energy storage device structure, eliminating separate harnesses and connectors. The circuit board serves dual purposes: electrical connection and structural support, thereby reducing component count and potential failure points while maintaining reliable electrical connectivity.
Solution Approach 2:
The patent removes the intermediary harnesses and connectors from the system, extracting only the essential electrical connection function and integrating it directly into the energy storage device structure. This simplification eliminates potential connection errors and reduces manufacturing complexity.
2Reliability
If multiple harnesses and connectors are used for electrical connections, then electrical connectivity is ensured, but manufacturing cost increases
Solution Approach 1:
The balancing circuit board is merged with the energy storage device structure, combining multiple functions (electrical connection, structural support, cell balancing) into a single integrated component. This eliminates the need for separate harnesses and connectors, reducing part count and manufacturing cost while ensuring reliable electrical connectivity.
Solution Approach 2:
The balancing circuit board serves multiple functions simultaneously: providing electrical connectivity, supporting the energy storage device structure, and performing cell balancing operations. This multi-functionality reduces the need for separate components, thereby lowering manufacturing cost while maintaining electrical reliability.
3Strength
If elastic members are used to support balancing circuit boards, then mechanical support is provided, but stress concentration may occur on the circuit board
Solution Approach 1:
The circuit board incorporates a cutout structure at the location where elastic members provide support. This local modification redistributes the mechanical stress, preventing stress concentration at critical points while maintaining the necessary mechanical support from the elastic members.
Solution Approach 2:
The cutout structure is designed in advance to accommodate and distribute the force from elastic members, providing beforehand cushioning against stress concentration. This preventive design feature protects the circuit board from potential damage while maintaining mechanical support.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The present invention relates to an energy storage device module comprising: a plurality of energy storage devices including a first energy storage device and a second energy storage device; a connection member configured to connect a first external terminal of the first energy storage device and a second external terminal of the second energy storage device adjacent to the first energy storage device; and a circuit board including a hole that passes through the first external terminal of the first energy storage device, a board protrusion supported by a curling processed portion formed in a body case of the first energy storage device, a first conductive metal layer formed in a region adjacent to the hole and in contact with the connection member, and a second conductive metal layer formed in a region of the board protrusion and in contact with the curling processed portion. Hereby, the present invention may reduce the cost necessary for preparing the harnesses and the connectors for cell balancing.