Battery Module Temperature Sensor Fixing via Flexible PCB
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Solution Overview
Problem
Conventional battery modules face increased manufacturing costs and complexity due to mechanically complicated fixing structures for temperature sensing elements, which are not sufficient for dynamic power demands and external impacts.
Innovation Solution
A battery module design featuring a temperature sensing element directly disposed on the battery cell surface, connected to a protection circuit module via a flexible printed circuit board, which reduces manufacturing complexity and cost by eliminating the need for routing and soldering, and using a rigid printed circuit board with a slit for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanically complicated fixing structure is used to maintain temperature sensing element position under external impact, then reliability of temperature measurement is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The temperature sensing element is integrated directly into the protection circuit module, eliminating the need for separate fixing structures. The sensing element is positioned to directly contact the battery cell surface through the circuit module housing, combining the sensing function with the protection circuit module structure.
Solution Approach 2:
A flexible printed circuit board is used as an intermediary to connect the temperature sensing element to the rigid printed circuit board. This flexible circuit board accommodates relative movement between the battery cell and protection circuit module while maintaining electrical connection and mechanical support for the sensing element.
2Stability of the object's composition
If multiple parts are used in the fixing structure, then stability of temperature sensing element position is improved, but ease of manufacture deteriorates
Solution Approach 1:
The temperature sensing element is integrated directly into the protection circuit module structure, reducing the number of separate parts. The sensing element is positioned through the housing of the circuit module and connected via the flexible printed circuit board, eliminating the need for multiple discrete fixing components.
Solution Approach 2:
The flexible printed circuit board provides dynamic accommodation for relative movement between the battery cell and protection circuit module. This flexibility allows the sensing element to maintain stable contact with the battery cell surface while the overall assembly can move relative to each other under external impact.
3Measurement precision
If a rigid fixing structure is used, then measurement precision is improved, but adaptability to relative movement deteriorates
Solution Approach 1:
The flexible printed circuit board replaces rigid mechanical fixing with a dynamic flexible connection. This allows the temperature sensing element to maintain precise contact with the battery cell surface while accommodating relative movement between the battery cell and protection circuit module through the flexibility of the circuit board.
Solution Approach 2:
The flexible printed circuit board acts as a flexible film structure that maintains electrical connection and mechanical support for the temperature sensing element while adapting to relative movement. The flexibility of this thin film structure allows it to bend and deform without breaking, maintaining measurement precision while adapting to movement.
Data Source
AI summary
The present invention relates to a battery module, and the battery module includes at least one battery cell, a protection circuit module that includes a rigid printed circuit board, and is electrically connected with the battery cell, at least one temperature sensing element provided at a surface of the battery cell, and a flexible printed circuit board that electrically connects the protection circuit module and the temperature sensing element.