Battery Pack Circuit Board Bending for Compact Stacked Unit Battery Coupling
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Solution Overview
Problem
Existing battery packs face challenges in achieving a compact and simple coupling structure between unit batteries, which affects their efficiency and safety, particularly in preventing overcharge and overdischarge.
Innovation Solution
A battery pack design featuring a circuit board with a flexible substrate and rigid substrates, where unit batteries are stacked and directly coupled to the circuit board through coupling terminals, allowing for efficient electrical connection and protection against overcharge and overdischarge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If unit batteries are coupled through complex wiring structures, then electrical connectivity is achieved, but device complexity increases and compactness is reduced
Solution Approach 1:
The patent merges the electrical connection function and mechanical support function into a single integrated circuit board structure. The circuit board directly couples multiple unit batteries through its substrate design, eliminating the need for separate wiring harnesses and coupling mechanisms, thereby reducing both device complexity and overall volume.
Solution Approach 2:
The patent transitions from planar wiring arrangements to a three-dimensional stacked configuration where unit batteries are arranged vertically on the circuit board. This dimensional change allows for more efficient space utilization and reduces the horizontal footprint of the battery pack while maintaining all necessary electrical connections.
2Adaptability or versatility
If flexible substrate is used for circuit board, then adaptability to battery stacking is improved, but structural strength is reduced
Solution Approach 1:
The patent employs a composite substrate structure combining flexible and rigid materials. The circuit board uses a flexible substrate base layer for adaptability, reinforced with rigid support elements and protective coatings to maintain sufficient mechanical strength while preserving the necessary flexibility for stacking configurations.
Solution Approach 2:
The patent implements different mechanical properties in different regions of the circuit board. The substrate has varying flexibility and stiffness zones - more flexible areas for adapting to battery contours and more rigid areas for providing structural support and maintaining electrical connection stability.
Data Source
AI summary
A battery pack includes a plurality of stacked unit batteries and a circuit board electrically coupled to the plurality of stacked unit batteries and being bent. The circuit board includes a first substrate including a bending portion and a second substrate on the first substrate layer and being less flexible than the first substrate layer.