Battery Module FPC Temperature Sensor Mounting Without Busbar Interference

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery modules face challenges in efficiently integrating a temperature sensor without interfering with peripheral components and optimizing the assembly structure, particularly when multiple battery cells are connected in series/parallel.

Innovation Solution

A battery module design incorporating a flexible printed circuit board unit with a temperature sensor, reinforced by a polycarbonate sheet, is attached to a busbar frame using a novel holding structure that minimizes interference and ensures stable positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a temperature sensor is assembled adjacent to the battery cell stack, then temperature measurement function is achieved, but interference with peripheral components occurs

Engineering Contradiction:

Improvetemperature measurementVSAvoidinterference with peripheral components

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The temperature sensor is integrated onto a flexible printed circuit board that can be positioned in three-dimensional space around the battery cell stack, allowing the sensor to reach optimal measurement positions without interfering with peripheral components like the busbar frame

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The flexible printed circuit board acts as an intermediary carrier that holds the temperature sensor, allowing the sensor to be positioned precisely adjacent to the battery cell stack while the FPC itself can route around peripheral components to avoid interference

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If a rigid structure is used for the temperature sensor assembly, then structural stability is improved, but ease of assembly deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoidease of assembly

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The flexible printed circuit board provides a dynamic solution where the FPC can be bent and shaped during assembly to fit complex spatial arrangements, yet maintains stable positioning once assembled, combining assembly flexibility with operational stability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible printed circuit board uses a thin, flexible substrate that can be easily manipulated during assembly processes, allowing simple attachment to the battery module structure while providing stable support for the temperature sensor in its final position

Inventive Principle:

Principle #30Flexible shells and thin films

3Manufacturing precision

If the flexible printed circuit board is held on the busbar frame, then positioning accuracy is improved, but device complexity increases

Engineering Contradiction:

Improvepositioning accuracyVSAvoidholding structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The busbar frame serves multiple functions: it provides electrical connections and also acts as a mounting structure for the flexible printed circuit board, eliminating the need for separate holding components and reducing overall device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12548805B2Battery module, manufacturing method thereof and battery pack

Publication Date: 2026.02.10 LG ENERGY SOLUTION LTD

AI summary

A battery module including a battery cell stack, which includes a plurality of battery cells; a busbar frame mounted on each of a front surface and a rear surface of the battery cell stack; a flexible printed circuit board unit to which a temperature sensor for measuring the temperature of the battery cell stack is attached; and a reinforcing sheet attached to the flexible printed circuit board unit.