Battery Module FPCB Connector Layout for Low-Height Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery modules face issues with flexible printed circuit board damage and increased height due to the use of a cover, as well as interference between electrode leads and busbar frames during assembly, which affects manufacturing efficiency and cost.
Innovation Solution
A battery module design that eliminates the flexible printed circuit board cover by using a connector to connect separated flexible printed circuit board parts, allowing vertical assembly of busbar frames and reducing the risk of damage during transportation and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible printed circuit board cover is used to protect the flexible printed circuit board, then the flexible printed circuit board is protected from damage, but the height of the battery module increases by 1.0 to 1.2 mm
Solution Approach 1:
The patent removes the flexible printed circuit board cover from the battery module structure. Instead of using a separate cover component, the flexible printed circuit board is directly installed within the frame, eliminating the need for the cover and thereby reducing the module height by 1.0 to 1.2 mm while maintaining protection through proper positioning and fixation structures
Solution Approach 2:
The patent integrates the flexible printed circuit board directly into the frame structure without a separate cover. The board is positioned and fixed within the frame using built-in positioning structures, merging the protection function into the existing frame rather than requiring an additional cover component
2Reliability
If the flexible printed circuit board is inserted into the frame while attached to the flexible printed circuit board cover, then the flexible printed circuit board is protected during assembly, but the height of the battery module increases
Solution Approach 1:
The patent extracts and removes the flexible printed circuit board cover from the assembly process. The board is inserted directly into the frame without being attached to a cover, eliminating the height increase while protection is maintained through proper insertion and fixation methods
3Ease of manufacture
If a hinge structure is used to assemble the busbar frame, then the busbar frame can be rotated into position, but interference occurs between the electrode leads and the rotating busbar frame
Solution Approach 1:
The patent applies preliminary action by pre-positioning the busbar frame in a vertical orientation relative to the battery cell stack before final assembly. This preliminary positioning prevents the rotating motion that causes interference with electrode leads, while still allowing for proper connection through the pre-aligned configuration
Solution Approach 2:
Instead of rotating the busbar frame horizontally into position (the conventional approach), the patent inverts the assembly approach by positioning the busbar frame vertically from the beginning. This reversal of the assembly sequence eliminates the interference problem while achieving the same connection function
4Length of stationary object
If the flexible printed circuit board is separated into two parts connected via a connector, then the board can be installed without a cover, but the assembly process becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the flexible printed circuit board into a first flexible printed circuit board part and a second flexible printed circuit board part. These separated parts can be independently positioned and connected via a connector, allowing direct installation into the frame without requiring a cover, while the segmentation simplifies the overall assembly process
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure relates to a battery module having a connector for connecting a flexible printed circuit board, and a manufacturing method thereof, and comprises: a battery cell stack in which a plurality of battery cells are stacked, first and second busbar frames formed respectively on front and rear surfaces of the battery cell stack, and a flexible printed circuit board connecting the first and second busbar frames, wherein the flexible printed circuit board includes a first flexible printed circuit board part and a second flexible printed circuit board part which are separated from each other, and the first flexible printed circuit board part and the second flexible printed circuit board part are connected to each other via a connector.