Battery Frame Assembly FPCB Bus Bar Connection
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Solution Overview
Problem
Flexible printed circuit boards (FPCBs) in hybrid and electric vehicles are prone to damage from external impacts due to their thin and lightweight nature, which complicates their integration and connection with bus bars in battery modules.
Innovation Solution
A frame assembly is designed where the connection circuit of the FPCB is directly bonded to bus bars using methods like laser welding, ultrasonic bonding, or resistance welding, with specific structural features such as recesses and plating layers to enhance stability and reduce the number of parts and welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a flexible printed circuit board (FPCB) is used to connect battery cells, then the battery module achieves lightweight and space-saving characteristics, but the FPCB becomes easily torn or damaged by external impact
Solution Approach 1:
The patent combines the FPCB with a rigid frame structure to create an integrated assembly. The FPCB is mounted on the frame with its circuit portions extending along the frame's surfaces, merging the flexibility and electrical functionality of the FPCB with the structural support and impact resistance of the frame, thereby maintaining lightweight characteristics while improving durability against external impacts
Solution Approach 2:
The invention creates a composite structure combining the flexible printed circuit board material with the rigid frame material. This composite assembly leverages the advantages of both materials: the FPCB provides electrical connectivity and flexibility, while the frame provides mechanical strength and impact resistance, resolving the contradiction between lightweight design and impact durability
2Volume of moving object
If the FPCB is made thinner to save space, then the battery module achieves higher space efficiency, but the FPCB becomes more susceptible to tearing and damage
Solution Approach 1:
The patent merges the thin FPCB with the rigid frame structure, where the frame provides the mechanical strength needed to prevent tearing. The FPCB maintains its thin profile for space efficiency while the frame absorbs impact forces, allowing the circuit board to remain thin without sacrificing tearing resistance
3Reliability
If traditional bonding methods are used to connect FPCB to bus bars, then connection stability is achieved, but the manufacturing process becomes complex with multiple welding steps
Solution Approach 1:
The patent merges the FPCB connection structure with the frame assembly, where the circuit portions extend directly along the frame surfaces and connect to bus bars mounted on the frame. This integrated design allows for simplified bonding processes compared to traditional separate FPCB mounting methods, reducing manufacturing complexity while maintaining connection stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the bonding process, reduces costs, and improves contact stability between the FPCB and bus bars, enhancing the durability and reliability of the battery module connections.
Implementation Method 1
The flexible printed circuit board may include a circuit portion disposed on the upper surface, a first connection circuit portion extending from a first end of the circuit portion and coupled to the plurality of first bus bars
Implementation Method 2
bonding methods (e.g., laser welding, ultrasonic bonding, resistance welding, and the like)
Implementation Method 3
bonding methods (e.g., laser welding, ultrasonic bonding, resistance welding, and the like)
Data Source
AI summary
Provided is a frame assembly for fixing a plurality of stacked battery cells. The frame assembly may include: a frame including an upper surface, a first side surface connected to a first end of the upper surface and a second side surface connected to a second end of the upper surface, the frame being configured to enclose the plurality of battery cells; a plurality of first bus bars disposed on the first side surface; a plurality of second bus bars disposed on the second side surface; and a flexible printed circuit board disposed along the upper surface, the first side surface, and the second side surface of the frame, the flexible printed circuit board being configured to sense the plurality of battery cells.