Battery Module FPC Sensing Structure for Cell Swelling
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Solution Overview
Problem
The existing rechargeable battery modules face challenges in handling the swelling of battery cells, which affects the connection between the sensing unit and the busbar, leading to defects and welding issues due to either excessively large or small sensing unit designs.
Innovation Solution
A rechargeable battery module design that includes a busbar holder, a busbar, and a flexible printed circuit (FPC) with a sensing unit connected via a slot hole and connection portion, where the slot hole's dimensions and placement absorb the swelling, and the connection widths are optimized to prevent defects and ensure stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the sensing unit is formed to have an excessively large shape to absorb flow, then the flow absorption capability is improved, but the handling difficulty and defect rate increase
Solution Approach 1:
The sensing unit is divided into multiple sensing patterns arranged in an array, with each pattern connected to the signal line through individual connection portions. This segmentation allows the sensing unit to maintain a compact overall shape while providing sufficient flow absorption capability through the distributed arrangement of multiple sensing patterns, thereby improving handling ease without sacrificing adaptability.
Solution Approach 2:
The sensing patterns are arranged in a two-dimensional array configuration rather than extending in a single linear direction. This dimensional arrangement enables the sensing unit to absorb flow in multiple directions simultaneously while maintaining a compact footprint, resolving the contradiction between flow absorption capability and handling difficulty.
2Ease of operation
If the sensing unit is formed to have an excessively small shape, then the handling ease is improved, but the flow absorption capability decreases and welding defects occur
Solution Approach 1:
The sensing unit comprises multiple sensing patterns that can be independently formed with optimized dimensions for easy handling, while collectively providing sufficient flow absorption capability. Each sensing pattern is connected through separate connection portions, allowing compact individual units to achieve cumulative flow absorption when arranged in an array.
Solution Approach 2:
The design optimizes the parameters of individual sensing patterns (size, shape, material properties) to achieve adequate flow absorption capability while maintaining a compact overall structure. By adjusting these parameters, the sensing unit achieves both easy handling and sufficient flow absorption without requiring excessive size.
3Strength
If the connection portion width is increased to protect from flow, then the connection strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The connection portion utilizes the flexible printed circuit board's inherent flexibility and thin film structure to achieve adequate connection strength. Rather than increasing the width of connection portions, the design relies on the FPCB's material properties and flexible characteristics to provide sufficient mechanical strength while maintaining manufacturing simplicity.
Solution Approach 2:
The design optimizes the dimensions and material parameters of connection portions to achieve the required connection strength with minimal width. By carefully selecting material properties and optimizing geometric parameters, the connection portions provide adequate strength without increasing manufacturing complexity.
Data Source
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AI summary
A rechargeable battery module is provided. The rechargeable battery module includes: a plurality of battery cells stacked in a first direction; a busbar holder configured to cover the battery cells while exposing electrode terminals of the battery cells in a third direction crossing a second direction from both sides of the second direction crossing the first direction; a busbar configured to connect the electrode terminals exposed to the busbar holder; and a flexible printed circuit connected to the busbar and covered with a film, wherein the flexible printing circuit includes: a body portion configured to form a plurality of signal lines in the film; a sensing unit connected to the busbar; a connection portion configured to form a connection line connecting the signal line and the sensing unit in the film and to have a connection width that is set; and a slot hole configured to pass through the film along a circumference of the sensing unit to form the connection portion and to have a penetration width.