Battery Module Flex Circuit With Redundant Traces for Thermal Runaway
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Solution Overview
Problem
Existing battery module monitoring systems require a complex and time-consuming wiring process, and are vulnerable to damage during thermal runaway events, which can disrupt monitoring capabilities.
Innovation Solution
A flexible printed circuit board with redundant conductive traces that connect battery module monitoring circuitry to battery cells without the need for a large wiring harness, providing protection from thermal runaway and ensuring continuous monitoring through redundant paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wiring harness with a large number of wires is used to connect monitoring circuitry to battery cells, then electrical connection to battery cells is achieved, but the wiring process becomes time-consuming and complex
Solution Approach 1:
The patent merges multiple individual wire connections into a single integrated flex circuit that connects to the battery current collector. The flex circuit contains multiple conductive traces that simultaneously establish electrical connections to multiple battery cells through the current collector, eliminating the need for separate wire routing for each cell and dramatically reducing assembly time.
Solution Approach 2:
The patent introduces the current collector as an intermediary component that facilitates connections between the flex circuit and battery cells. The current collector serves as a common interface that already connects to multiple battery cells, allowing the flex circuit to establish monitoring connections through this intermediary rather than requiring direct wire connections to each cell.
2Reliability
If wires are routed through the battery module to connect monitoring circuitry, then electrical connection is achieved, but the wires may be damaged during thermal runaway events
Solution Approach 1:
The patent extracts the monitoring circuitry and its connection paths from the interior of the battery module. By routing the flex circuit through the housing rather than through the battery cell array, the conductive traces are removed from the hazardous environment where thermal runaway could occur, protecting them from damage while maintaining monitoring capability.
Solution Approach 2:
The patent changes the spatial dimension of the connection path by moving it from the internal three-dimensional space among battery cells to the external surface of the battery module housing. This dimensional relocation places the conductive traces in a safer zone away from thermal runaway events while still enabling electrical connection to the battery cells through the current collector.
3Reliability
If redundant conductive traces are implemented in the flex circuit, then monitoring continues during thermal runaway events, but the device complexity increases
Solution Approach 1:
The patent implements multi-functionality in the flex circuit by designing conductive traces that serve dual purposes: they provide electrical connection paths for monitoring and simultaneously act as protective redundant paths. During normal operation, all traces function for monitoring; during thermal runaway events, intact traces continue to provide monitoring capability, making the system adaptable to different operational conditions without requiring separate protective mechanisms.
Data Source
AI summary
A flex circuit and a battery module including the flex circuit are provided. The flex circuit includes a first plurality of conductive traces and a second plurality of conductive traces. Each of the first plurality of conductive traces includes a first terminal configured to be electrically coupled to a first location of a respective one of a plurality of busbars that electrically connect battery cells of the battery module, and a second terminal configured to be electrically coupled to processing circuitry. Each of the second plurality of conductive traces includes a first terminal configured to be electrically coupled to a second location of a respective one of the plurality of busbars, and a second terminal configured to be electrically coupled to the processing circuitry. The processing circuitry is configured to measure a voltage level of each of the plurality of busbars using the first and second plurality of conductive traces.