Battery Pack Flexible Conductor Layout for Cell Sensing
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Solution Overview
Problem
Existing battery packs for electric vehicles face inefficiencies due to complex and costly cable arrangements for cell-sensing and current collection, which occupy valuable space and increase weight and complexity.
Innovation Solution
A flexible conductor arrangement using a combination of flexible printed circuits (FPCs) and flexible flat cables (FFCs) that branch to connect battery management modules with sensor devices and current collector devices, reducing the need for additional cables and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable arrangements are used for cell-sensing and current collection, then reliable electrical connections are achieved, but the battery pack occupies more space, increases in weight, and becomes more complex
Solution Approach 1:
The patent combines multiple separate cable functions into a single integrated flexible printed circuit board (FPCB) structure. The FPCB integrates both cell-sensing connections and current collection functions that were previously handled by separate cable arrangements, thereby reducing overall complexity while maintaining reliable electrical connections across all battery cells.
Solution Approach 2:
The patent replaces traditional mechanical cable assemblies with a flexible printed circuit board system. This substitution eliminates the need for bulky connectors, insulation layers, and manual routing associated with traditional cables, while providing more consistent and reliable electrical connections through precision-manufactured conductive traces on the FPCB.
2Reliability
If traditional cable arrangements are used for cell-sensing and current collection, then electrical connections are established, but the battery pack weight increases
Solution Approach 1:
The patent replaces heavy traditional cable assemblies with lightweight flexible printed circuit boards. The FPCB construction using thin copper traces on flexible substrate significantly reduces weight compared to equivalent cable arrangements with insulation, connectors, and shielding, while maintaining reliable electrical connections for both sensing and current collection.
Solution Approach 2:
The patent utilizes thin flexible printed circuit board films to replace bulky cable assemblies. The FPCB structure employs thin flexible substrates with conductive traces that provide the necessary electrical connectivity with minimal mass, directly addressing the weight reduction goal while preserving connection reliability.
3Measurement precision
If more cables and components are added for battery management, then sensing and control capabilities are improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent merges multiple sensing and control functions into a single FPCB structure that serves both cell-sensing and current collection purposes. This integration reduces the total component count and simplifies manufacturing, as the FPCB can be pre-assembled with appropriate circuitry before installation, eliminating the need for complex on-site cable routing and connector assembly.
Solution Approach 2:
The FPCB structure performs multiple functions simultaneously: it provides cell-sensing connections, current collection paths, and structural support. This multi-functionality reduces the number of separate components needed, thereby lowering manufacturing costs and simplifying assembly operations while maintaining precise measurement capabilities across all battery cells.
Data Source
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AI summary
The present disclosure refers to a battery pack (10), comprising: a plurality of battery cells (20), at least one battery management module, BMM (21), a plurality of sensor devices (25a) and/or current collector devices (25b), a flexible conductor arrangement (22) comprising a plurality of conductor lines (14), wherein the flexible conductor arrangement (22) comprises at least one flexible printed circuit, FPC, (23, 23a, 23b) and a plurality of flexible flat cables, FFCs, (24) connected to the FPC (23, 23a, 23b), wherein the conductor lines (14) are routed along the FPC (23, 23a, 23b) and branch into the plurality of FFCs (24), and wherein each of the conductor lines (14) electrically interconnects the BMM (21) via the FPC (23, 23a, 23b) and via one of the FFCs (24) with one of the sensor devices (25a), one of the current collector devices (25b) and/or one of the battery cells (20).