Battery Module Flexible Circuit Board Sampling Integration
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Solution Overview
Problem
Conventional battery modules have complex and bulky sampling structures due to direct wiring connections, which complicate assembly, increase the risk of errors, and require manual assembly, leading to potential safety issues and inefficiencies in production.
Innovation Solution
A battery module design featuring a flexible circuit board with integrated temperature sensors and voltage sampling terminals, bonded and fixed using inner and external insulating layers, simplifying assembly and enhancing safety through reduced volume and automated production capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring sampling pattern is used, then voltage and temperature sampling can be achieved, but the circuitry becomes complex and manual assembly is required which increases assembly errors and reduces productivity
Solution Approach 1:
The patent integrates voltage sampling terminals and temperature sensors onto a single bus bar assembly, combining multiple sampling functions into one unified structure. This eliminates the need for separate wiring connections for each battery cell, significantly simplifying the circuitry while maintaining reliable voltage and temperature sampling capabilities.
Solution Approach 2:
The bus bar assembly serves multiple functions simultaneously: it provides electrical connection between battery cells, integrates voltage sampling terminals for electrical measurement, and incorporates temperature sensors for thermal monitoring. This multi-functionality eliminates the need for separate dedicated sampling wiring, reducing overall system complexity.
2Reliability
If conventional wiring sampling pattern is used, then sampling can be performed, but manual assembly is required which reduces productivity and increases assembly errors
Solution Approach 1:
By integrating voltage sampling terminals and temperature sensors directly into the bus bar assembly structure, the patent enables all sampling components to be installed simultaneously during the standard battery assembly process. This eliminates separate manual wiring steps, significantly improving productivity while ensuring consistent sampling reliability through standardized integration.
3Reliability
If conventional wiring sampling pattern is used, then voltage and temperature sampling can be achieved, but special fixing devices are required which increase device complexity and wiring sheaths are prone to abrasion causing current leakage
Solution Approach 1:
The patent integrates voltage sampling terminals and temperature sensors directly onto the bus bar assembly, eliminating the need for separate wiring connections and their protective sheaths. This integration removes the source of sheath abrasion and current leakage risks while maintaining stable sampling through direct electrical and thermal contact with the bus bar.
4Quantity of substance
If battery module has high volume to ensure capacity, then energy storage capacity increases, but the structure becomes bulky and complex
Solution Approach 1:
The patent integrates multiple sampling functions (voltage measurement and temperature monitoring) directly into the bus bar assembly structure, combining what would traditionally be separate components into one unified element. This integration significantly simplifies the overall module structure, reducing structural complexity while maintaining the necessary monitoring capabilities for high-capacity battery operation.
Data Source
AI summary
A battery module is provided. The battery module may comprise: a battery pack comprising a plurality of single batteries (6) and a plurality of power splicers (3) for electrically connecting adjacent single batteries (6); a sampling module comprising a flexible circuit board (1), in which a plurality of voltage sampling terminals (7) and a plurality of temperature sensors (4) are disposed on the flexible circuit board (1) respectively, each voltage sampling terminal (7) is electrically connected with each power splicer (3), and each temperature sensor (4) is connected with each power splicer (3); and a shell for receiving the battery pack and the sampling module.