Battery Pack Circuit Board Layout for Vibration-Resistant Bus Bar Links
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Solution Overview
Problem
Existing battery packs face issues with circuit board disconnection due to reduced durability, primarily caused by excessive bending and curvature of circuit patterns, which are prone to damage from vibrations.
Innovation Solution
The battery pack design includes a circuit board with straight, obliquely extending second portions that connect to the bus bar, featuring circuit patterns with alternating convex and concave shapes and dummy patterns to enhance rigidity, reducing the overall length and vulnerability to damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the circuit board uses bent or curved circuit patterns to connect components, then the circuit board can accommodate complex layouts and connect more components, but the durability and reliability of the circuit board decrease due to vibration-induced damage
Solution Approach 1:
The circuit board is divided into multiple rigid support portions extending from the central processing area toward the edges. These support portions are segmented and distributed to provide localized reinforcement at critical stress points, allowing the circuit board to maintain overall rigidity while accommodating complex circuit layouts between the support structures.
Solution Approach 2:
The patent transitions from a two-dimensional flexible circuit layout to a three-dimensional rigid structure by adding vertical support portions that extend upward from the circuit board plane. This dimensional change creates a rigid framework that prevents vibration-induced damage while maintaining the necessary circuit connectivity through conductive traces on the support portions.
2Reliability
If the circuit board uses straight, rigid support portions, then the durability and vibration resistance improve, but the ability to accommodate complex circuit layouts and component placement is reduced
Solution Approach 1:
The support portions serve multiple functions simultaneously: they provide mechanical reinforcement to resist vibration, act as structural supports for mounting components, and function as conductive traces for electrical connectivity. This multi-functionality allows the rigid support structure to maintain durability while accommodating complex circuit layouts through its dual role as both structural and electrical element.
3Adaptability or versatility
If the circuit board extends longer to connect more components, then the functionality and component integration increase, but the vulnerability to vibration damage and disconnection increases
Solution Approach 1:
The support portions are strategically positioned and dimensioned to provide preemptive mechanical reinforcement to areas of the circuit board that would be most vulnerable to vibration damage. By placing rigid supports at critical locations before vibration occurs, the design prevents damage proactively rather than reacting to it, allowing longer circuit board extensions to connect more components without increasing vulnerability.
Data Source
AI summary
A battery pack includes a battery module including battery cells and a bus bar configured to electrically connect the battery cells, and a circuit board connected to the battery module that includes a first portion extending in a longitudinal direction of the battery module, second portions extending from the first portion in a direction crossing the first portion that each include a circuit pattern, and a third portion connected to an end of each of the second portions and connected to the bus bar. Each second portion extends straight without being bent or folded.