Car Battery System with Integrated Circuit Board
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Solution Overview
Problem
Existing car battery systems face challenges in accurately detecting battery cell voltage due to high impedance in long wire-harnesses, leading to reduced measurement accuracy and increased risks of malfunction, smoke, and fire from short circuits or open circuits.
Innovation Solution
A car battery system with a single-sided circuit board mounted opposite the terminal plane of a battery block, connecting battery cell terminals directly to minimize line impedance and prevent short circuits, allowing for precise voltage measurements and improved safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wire-harnesses with long wire-leads are used to connect battery cells to the detection circuit, then the battery system can be assembled with the circuit board disposed outside the battery block, but the line impedance increases and measurement precision deteriorates
Solution Approach 1:
The circuit board is moved from an external position to an integrated position within the battery block, changing the spatial dimension of the connection. This integration allows the use of short trace-leads instead of long wire-leads, significantly reducing line impedance while maintaining assembly flexibility through the standardized circuit board design.
Solution Approach 2:
The detection circuit and battery block are merged into a single integrated unit. The circuit board is disposed inside the battery block and directly connected to battery cell terminals, combining the detection function with the battery structure. This eliminates the need for separate wire-harnesses and reduces measurement impedance.
2Ease of operation
If wire-harnesses with long wire-leads are used, then the circuit board can be disposed outside the battery block, but the impedance differences among wire-leads increase causing detection errors
Solution Approach 1:
The circuit board transitions from an external component to an internal component within the battery block. This dimensional change allows all connections to be made through short trace-leads on the circuit board, eliminating impedance variations that occur with wire-harnesses of different lengths while maintaining circuit board accessibility for detection purposes.
3Ease of manufacture
If wire-harnesses are used to bundle wire-leads together, then connections can be made between battery cells and detection circuit, but the risk of short circuits and open circuits increases
Solution Approach 1:
The wire-harness and bundled wire-leads are extracted and replaced with direct trace-lead connections on the circuit board. This eliminates the physical wire-harness that could suffer from short circuits or open circuits, while the trace-leads on the circuit board provide stable, controlled connections between battery terminals and the detection circuit.
Solution Approach 2:
The circuit board serves as an intermediary between the battery terminals and the detection circuit. Instead of directly connecting wire-leads that could short or open, the circuit board provides a controlled, stable connection path through its trace-leads, reducing the risk of harmful electrical faults.
4Ease of operation
If wire-harnesses with long wire-leads are used, then the battery system can accommodate external circuit board placement, but manufacturing cost increases
Solution Approach 1:
The detection circuit board is merged with the battery block structure, with the circuit board disposed inside the battery block. This integration eliminates the need for separate wire-harnesses and long wire-leads, reducing material costs and assembly complexity while maintaining the ability to install and access the circuit board for detection functions.
Data Source
AI summary
The car battery system of the present invention is provided with a battery block 2 that retains a plurality of battery cells 1 in a stacked configuration and has a terminal plane 2A, which is coincident with terminal surfaces 1A established by positive and negative battery cell 1 electrode terminals 13; and with a battery state detection circuit 30 that connects with the electrode terminals 13 of each battery cell 1. The battery system is provided with a circuit board 7 with surface-mounted electronic components 40 that implement the battery state detection circuit 30. The circuit board 7 is a single-sided board with electronic components 40 mounted on only one side, and the circuit board 7 is attached to the battery block 2 opposite the terminal plane 2A with the side having no electronic components 40 facing the battery block 2. The positive and negative electrode terminals 13 of each battery cell 1 are connected with the circuit board 7 for connection to the battery state detection circuit 30.