Battery Module FFC Busbar Connection for Lower Height and Weight
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Solution Overview
Problem
Conventional battery modules suffer from increased height and weight due to the use of cover plates over flexible printed circuits, leading to space and weight inefficiencies, which negatively impact vehicle performance and fuel efficiency.
Innovation Solution
The battery module employs a flexible flat cable (FFC) connection part that replaces the cover plate, allowing for automatic assembly and reducing module height and weight, while maintaining electrical connectivity between busbar frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover plate is disposed above the flexible printed circuit board to prevent damage, then the reliability of the flexible printed circuit board is improved, but the height and weight of the battery module increase
Solution Approach 1:
The patent removes the cover plate from the battery module structure, extracting the protective function and replacing it with an alternative approach. The flexible printed circuit board is routed through a groove in the end plate rather than being protected by a separate cover plate, thereby reducing height while maintaining protection.
Solution Approach 2:
The protective function previously provided by a separate cover plate is merged into the end plate structure itself. The end plate incorporates a groove that both protects the flexible printed circuit board and integrates the protection function into the existing structural component, eliminating the need for an additional cover plate.
2Reliability
If a cover plate is disposed above the flexible printed circuit board to prevent damage, then the reliability of the flexible printed circuit board is improved, but the weight of the battery module increases
Solution Approach 1:
The cover plate is extracted from the battery module structure, removing its weight while maintaining the protective function through the integrated groove design in the end plate.
Solution Approach 2:
The protection function is merged into the end plate, eliminating the need for a separate cover plate and thereby reducing the overall weight of the battery module while maintaining reliability.
3Area of stationary object
If the height of the battery module is reduced by removing the cover plate, then the space utilization efficiency is improved, but the flexible printed circuit board may be damaged
Solution Approach 1:
The end plate is designed with an integrated groove that provides protection for the flexible printed circuit board while maintaining the reduced height profile. This merging of protection into the structural end plate achieves both space efficiency and reliability.
Solution Approach 2:
The groove in the end plate acts as an intermediary structure that protects the flexible printed circuit board without requiring a separate cover plate. The groove provides the necessary protection while maintaining the compact design.
4Weight of stationary object
If the weight of the battery module is reduced by removing the cover plate, then the fuel efficiency is improved, but the flexible printed circuit board may be damaged
Solution Approach 1:
The cover plate is removed to reduce weight, and its protective function is replaced by the integrated groove design in the end plate, achieving weight reduction without sacrificing reliability.
Solution Approach 2:
The protection function is merged into the end plate structure, eliminating the need for a separate cover plate and thereby reducing weight while maintaining the protective capability for the flexible printed circuit board.
Data Source
AI summary
Discussed is a battery module which includes: a battery cell stack in which a plurality of battery cells are stacked; a lower frame that covers a lower surface and both side surfaces of the battery cell stack; an upper frame that covers an upper surface of the battery cell stack; busbar frames that respectively cover front front and rear surfaces of the battery cell stack; and a connector that connects the busbar frame at the front surface with the busbar frame at the rear surface, wherein the connector is formed of a flexible flat cable (FFC) and attached to the upper frame.