Battery Module FFC Sensing Layout 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 circuit boards, leading to space and weight inefficiencies that negatively impact installation and vehicle performance.
Innovation Solution
A battery module design utilizing a flexible flat cable (FFC) connection unit that eliminates the need for a cover plate, connecting busbar frames directly, thereby reducing module height and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover plate is provided over the flexible printed circuit board to prevent damage, then the reliability of the circuit board is improved, but the height and weight of the battery module increase
Solution Approach 1:
The patent extracts and removes the cover plate from the battery module structure, replacing it with a flexible flat cable that integrates the circuit board function without requiring additional protective housing, thereby reducing module height while maintaining circuit board protection through the cable's inherent flexibility and routing design
Solution Approach 2:
The patent employs a flexible flat cable instead of a rigid cover plate structure, utilizing the flexible nature of the cable to provide both circuit connection and protection without adding significant height, as the flexible cable can be routed and positioned within the existing module space
2Reliability
If a cover plate is provided over the flexible printed circuit board to prevent damage, then the reliability of the circuit board is improved, but the weight of the battery module increases
Solution Approach 1:
The patent removes the cover plate component entirely, eliminating its weight contribution to the battery module while maintaining circuit board protection through the flexible flat cable's integrated design and routing strategy
Solution Approach 2:
The flexible flat cable combines multiple functions (circuit connection, protection, and routing) into a single composite structure, replacing the separate cover plate and circuit board assembly, thereby reducing overall weight while maintaining protective functionality
3Reliability
If the battery module height is increased due to the cover plate, then the circuit board is protected, but the installation space requirement increases
Solution Approach 1:
By removing the cover plate, the patent reduces the vertical dimension of the battery module, allowing for more compact installation configurations and reduced space requirements in applications such as electric vehicles
Solution Approach 2:
The patent transitions from a vertical protection approach (cover plate adding height) to a horizontal/routed protection approach (flexible cable routing), effectively changing the dimensional strategy for achieving protection without increasing overall module height
4Reliability
If the battery module weight is increased due to the cover plate, then the circuit board is protected, but the fuel efficiency decreases
Solution Approach 1:
The removal of the cover plate eliminates unnecessary weight that contributes to energy consumption during vehicle operation, directly improving fuel efficiency while maintaining adequate protection of the circuit board through the flexible flat cable design
Data Source
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AI summary
The present disclosure relates to a battery module and a battery pack including the same, and more particularly, to a battery module including an improved sensing connection member. The battery module includes a battery cell stack in which a plurality of battery cells are stacked, a lower frame covering a bottom surface and both side surfaces of the battery cell stack, an upper frame covering an upper surface of the battery cell stack, a busbar frame formed on each of front and rear surfaces of the battery cell stack, and a connection unit that connects the bus bar frame, wherein the connection unit is formed of a flexible flat cable (FFC) and is located between the upper frame and the battery cell stack.