Battery Pack Control Module Integration for Compact Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery systems face challenges in accommodating smaller device designs due to space constraints, as larger batteries require more housing space and restrict the placement of associated components, limiting the available volume and geometry for battery cells and control systems.
Innovation Solution
The proposed battery system configuration includes a module with a circuit board and conductive tabs that electrically couple with the battery terminals, allowing for compact positioning and flexible coupling to accommodate the battery's geometry, thereby reducing the overall system envelope and increasing battery capacity within smaller devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If larger batteries are used to increase capacity, then battery capacity is improved, but device size and housing space requirements increase
Solution Approach 1:
The control system components (control circuit, protection circuit, management chip) are integrated into a single module that is positioned within the battery's housing space. This merging of control functions into a compact module allows the battery to achieve higher capacity without proportionally increasing overall device volume, as the control system no longer occupies separate external space.
Solution Approach 2:
The control module is nested within the battery housing structure, utilizing the existing space between battery cells and within the battery assembly. The module is positioned in the available volume between cells, effectively nesting the control system within the battery's own structural envelope rather than requiring additional external space.
2Volume of moving object
If battery housing space is reduced to decrease device size, then device volume is reduced, but placement options for battery cells and control systems are limited
Solution Approach 1:
The control module incorporates a flexible circuit board that can be bent and shaped to accommodate various battery geometries and configurations. This flexibility allows the module to adapt to different placement scenarios within constrained spaces, maintaining versatility in placement options even when housing volume is reduced. The flexible coupling enables the module to conform to irregular spaces between battery cells.
Solution Approach 2:
The control module utilizes a flexible printed circuit board (FPC) as its structural substrate, allowing the entire module to be bent, folded, or shaped to fit within tight and irregular spaces. This flexible film structure replaces rigid circuit boards, enabling the control system to adapt to various battery configurations without requiring fixed, pre-determined placement locations.
3Volume of moving object
If control system components are integrated into a module to save space, then space efficiency is improved, but electrical coupling complexity increases
Solution Approach 1:
Multiple electrical connections (positive terminal coupling, negative terminal coupling, and signal connections to battery management chip) are merged into a single integrated control module. The flexible circuit board integrates multiple conductive traces and connection points, consolidating what would otherwise be separate wiring harnesses and connection points into one unified structure, thereby reducing overall electrical coupling complexity.
Solution Approach 2:
The flexible circuit board acts as an intermediary structure that provides organized electrical pathways between the battery terminals and the control circuit components. Instead of requiring direct, complex wiring between multiple discrete components, the flexible circuit board mediates all electrical connections through its integrated trace network, simplifying the electrical coupling architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables efficient use of limited space in devices by allowing for a controlled form factor of battery control system components, enhancing battery capacity and accommodating various device geometries while maintaining a compact footprint.
Implementation Method 1
a first adhesive positioned between the second conductive tab and the mold proximate the port
Data Source
AI summary
Battery systems according to embodiments of the present technology may include a battery. The battery may include a first electrode terminal and a second electrode terminal accessible along a first surface of the battery. The systems may include a module electrically coupled with the battery. The module may include a circuit board characterized by a first surface and a second surface opposite the first surface. The module may include a mold extending from the first surface of the circuit board toward the battery. The module may include a first conductive tab electrically coupling the module with the first electrode terminal. The module may include a second conductive tab electrically coupling the module with the second electrode terminal. The second conductive tab may extend across the mold substantially parallel to the first surface of the circuit board.