Battery Connection Module Flexible Circuit Board Integration
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Solution Overview
Problem
Existing battery connection modules require multiple connectors for connecting batteries in series and integrating a battery management system, leading to increased complexity and cost.
Innovation Solution
A battery connection module comprising a carrying tray, busbars, a battery management system, and a flexible circuit board, where the battery management system is directly mounted on the tray and electrically connected via the flexible circuit board, reducing the need for multiple connectors and allowing for flexible positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple connectors are used to connect batteries in series and integrate the battery management system, then the connection reliability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent combines multiple separate connectors into a single integrated connector that simultaneously connects the battery management system to multiple busbars. This single connector integrates multiple connection functions, reducing the total number of connectors while maintaining reliable electrical connections between the battery management system and all necessary busbars, thereby resolving the contradiction between connection reliability and device complexity
2Reliability
If multiple connectors are used to connect batteries in series and integrate the battery management system, then the connection reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple separate connector components into one integrated connector structure. This consolidation reduces the total component count, simplifies the manufacturing process, reduces assembly steps, and lowers overall manufacturing cost while maintaining the necessary connection reliability through the integrated design
3Reliability
If a rigid circuit board is used to connect the battery management system to busbars, then the electrical connection is stable, but the positioning flexibility is reduced
Solution Approach 1:
The patent employs a flexible circuit board instead of a rigid one to connect the battery management system to the busbars. The flexible circuit board maintains stable electrical connections through its conductive traces while allowing the battery management system to be positioned at various locations on the carrying tray, thus providing both connection stability and positioning flexibility
Data Source
AI summary
A battery connection module is adapted to connect a battery pack, the battery connection module comprises: a carrying tray; a plurality of busbars mounted on the carrying tray and adapted to electrically connect a plurality of batteries of the battery pack; a flexible circuit board mounted on the carrying tray and mechanically and electrically connected to the plurality of busbars, the flexible circuit board having a frame-shaped portion with an opening, a flexible mating portion being provided in the opening of the frame-shaped portion; and a battery management system mounted on the carrying tray, positioned above the flexible circuit board and comprising a flexible circuit board connector; the flexible mating portion extending into the opening and being reversely bent and mated with the flexible circuit board connector on the battery management system. These components are integrated to an integrated module that facilitates subsequent assembling and use.