Battery Module Busbar-FPC Layout for Cell Swelling Stability
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Solution Overview
Problem
Rechargeable battery modules face issues with swelling of battery cells causing the aluminum busbar to shift, affecting the flexible printed circuit and sensing tab connections, leading to handling difficulties, welding defects, and curling phenomena due to inadequate absorption of flow.
Innovation Solution
A rechargeable battery module design featuring a busbar holder, flexible printed circuit with a body portion, sensor, and slot hole configuration that absorbs flow from the busbar, protecting the connection between the sensor and busbar, using materials like aluminum and copper for the busbar and sensor, and bonding methods such as ultrasonic welding or anisotropic conductive film bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is formed to have an excessively large shape to absorb flow, then flow absorption capability is improved, but handling difficulty and fixing defects increase
Solution Approach 1:
The sensor is divided into a body portion and a connection portion separated by a slot hole. The connection portion has a narrower width than the body portion, creating a segmented structure that reduces the overall footprint while maintaining flow absorption capability through the larger body portion.
Solution Approach 2:
Different portions of the sensor have different widths to serve different functions. The body portion has a larger width for effective flow absorption, while the connection portion has a narrower width for easier handling and connection, optimizing each region's properties locally.
2Ease of operation
If the sensor is formed to have an excessively small shape for easy handling, then handling ease is improved, but flow absorption capability decreases and curling occurs
Solution Approach 1:
The sensor structure is segmented into body and connection portions with a slot hole in between. This segmentation allows the body portion to be larger for flow absorption while the connection portion remains smaller for easy handling, resolving the size conflict.
Solution Approach 2:
The slot hole creates a dimensional separation between the body and connection portions. By utilizing this spatial dimension, the sensor can have a larger effective area for flow absorption without proportionally increasing the overall footprint, maintaining handling ease.
3Area of stationary object
If the connection portion has narrow width to reduce footprint, then space utilization is improved, but connection reliability and protection from flow decrease
Solution Approach 1:
The slot hole acts as an intermediary protective structure between the busbar and the connection portion. It serves as a barrier that prevents direct flow contact with the connection portion while allowing the connection to maintain its narrower, space-efficient dimensions.
Solution Approach 2:
The slot hole is positioned to preemptively block the flow path before it can reach the connection portion. This preliminary protective action prevents flow-induced damage to the connection while allowing the connection portion to maintain its compact design.
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 design effectively absorbs flow from the busbar, preventing connection defects and curling, while maintaining structural integrity and stability during manufacturing and operation.
Implementation Method 1
A rechargeable battery module design featuring a busbar holder, flexible printed circuit with a body portion, sensor, and slot hole configuration that absorbs flow from the busbar
Implementation Method 2
The welded portion of the busbar and the sensor may ultrasonic welded, laser welded, or spot welded
Implementation Method 3
The busbar and the sensor may be bonded by anisotropic conductive film (ACF) bonding, soldering bonding, or mechanical bonding
Data Source
AI summary
A rechargeable battery module is provided. The rechargeable battery module may include battery cells aligned in a first direction, a busbar holder configured to cover the battery cells while exposing electrode terminals of the battery cells, a busbar configured to connect the electrode terminals, and a flexible printed circuit connected to the busbar, covered with a film, and including a body portion including signal lines in the film, a sensor coupled to the busbar, a connection portion including a connection line connecting the signal line and the sensor in the film, and having a connection width, and a slot hole passing through the film along a perimeter of the sensor to define the connection portion, and having a penetration width.