Battery Module FFC Layout for Lower Height and Busbar Reliability
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Solution Overview
Problem
Conventional battery modules are bulky and heavy due to the use of cover plates with flexible printed circuit boards, leading to increased installation space requirements and decreased vehicle performance and fuel efficiency when installed in vehicles.
Innovation Solution
A battery module design that replaces the cover plate with a flexible flat cable (FFC) connection unit between busbar frames, reducing module height and weight, and includes a U-shaped lower frame, an upper frame, and busbar frames to connect battery cells efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover plate with flexible printed circuit board is used to connect busbar frames, then the connection is protected and reliable, but the battery module height and weight increase
Solution Approach 1:
The patent extracts and removes the cover plate from the battery module structure, retaining only the essential flexible printed circuit board for electrical connection. This eliminates the protective cover that contributed to height increase while maintaining the core functional connection capability.
Solution Approach 2:
The patent employs a flexible printed circuit board as a thin-film solution to replace the bulky cover plate structure. The flexible circuit board provides both mechanical support and electrical connection in a compact form factor, significantly reducing the height requirement while maintaining connection reliability.
2Reliability
If a cover plate with flexible printed circuit board is used to connect busbar frames, then the connection is protected and reliable, but the battery module weight increases
Solution Approach 1:
The patent extracts and removes the cover plate from the battery module structure, retaining only the essential flexible printed circuit board for electrical connection. This eliminates the protective cover that contributed to weight increase while maintaining the core functional connection capability.
Solution Approach 2:
The patent employs a flexible printed circuit board as a thin-film solution to replace the bulky cover plate structure. The flexible circuit board provides both mechanical support and electrical connection in a compact form factor, significantly reducing the weight while maintaining connection reliability.
3Reliability
If the battery module size is increased to accommodate cover plate and FPC, then connection protection is improved, but installation space requirement increases
Solution Approach 1:
The patent extracts and removes the cover plate from the battery module structure, retaining only the essential flexible printed circuit board for electrical connection. This eliminates the protective cover that contributed to height increase while maintaining the core functional connection capability.
Solution Approach 2:
The patent employs a flexible printed circuit board as a thin-film solution to replace the bulky cover plate structure. The flexible circuit board provides both mechanical support and electrical connection in a compact form factor, significantly reducing the height requirement while maintaining connection reliability.
Data Source
AI summary
The present disclosure relates to a battery module and a battery pack including the same, and more particularly, to a battery module including an improved sensing connection member. The battery module includes a battery cell stack in which a plurality of battery cells are stacked, a lower frame covering a bottom surface and both side surfaces of the battery cell stack, an upper frame covering an upper surface of the battery cell stack, a busbar frame formed on each of front and rear surfaces of the battery cell stack, and a connection unit that connects the bus-bar frame, wherein the connection unit is formed of a flexible flat cable (FFC) and is located between the upper frame and the battery cell stack.