Battery Module FPCB Sensing Layout for Compact Shock Resistance

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Solution Overview

Problem

Existing battery modules with slidably-coupled sensing blocks face challenges in achieving improved energy efficiency per volume and are at risk of damage from impact.

Innovation Solution

The battery module incorporates a design with front and rear bus bars, rigid and flexible printed circuit boards (RPCBs and FPCBs), and wire connections to efficiently sense and transmit voltage and temperature information, while minimizing size and enhancing structural support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a sensing block is slidably-coupled to the upper housing to improve assembling characteristic, then the assembling characteristic is improved, but the overall volume increases, thereby lowering energy efficiency per volume

Engineering Contradiction:

Improveassembling characteristicVSAvoidoverall volume

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

The sensing block is integrated with the upper housing through direct formation or rigid connection, merging two previously separate components into one unified structure. This eliminates the need for slidable coupling mechanisms while maintaining electrical connectivity for voltage sensing, thereby reducing overall volume without compromising assembly ease.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensing function is extracted from a separate slidable sensing block and incorporated directly into the upper housing structure. The voltage sensing capability is maintained through direct electrical contacts formed on the housing itself, eliminating the need for additional sensing components and reducing overall module volume.

Inventive Principle:

Principle #2Taking out (Extraction)

2Volume of stationary object

If the module volume is reduced to improve energy efficiency per volume, then energy efficiency per volume is improved, but the structural support may be compromised, increasing risk of damage from impact

Engineering Contradiction:

Improvemodule volumeVSAvoidrisk of damage from impact

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

The upper housing is constructed from high-strength, impact-resistant materials that provide superior structural support per unit volume. These composite materials maintain structural integrity and protection against impact damage while enabling compact module design, thus improving energy efficiency per volume without compromising reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The housing structure incorporates built-in shock-absorbing features and protective design elements that mitigate impact damage before it reaches internal components. This preemptive protection allows for compact design while maintaining reliability against external shocks.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20250192383A1Battery module

Publication Date: 2025.06.12 SK ON CO LTD

AI summary

A battery module which uses a flexible printed circuit board (FPCB) to provide a transmission path of information on the voltage or temperature thereof sensed by a bus bar. The battery module may have a smaller size in a height direction compared to a case of using a rigid printed circuit baord (RPCB) or a wire instead of the FPCB to provide the transmission path of the information on the voltage or temperature, and may thus have improved energy efficiency per volume.