Battery Pack Flex Circuit Coupling for Bending Resistance
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Solution Overview
Problem
Battery packs face challenges in maintaining the rigidity of flexible circuit boards when subjected to tensile or bending forces, which can lead to damage and disruption of the coupling between the flexible circuit board and other circuit boards.
Innovation Solution
The design includes a battery pack with a main circuit board and a flexible circuit board connected via coupling pads and bonding material, where the coupling pads are strategically arranged and shaped to enhance resistance to tension and bending forces, ensuring the flexible circuit board remains intact and coupled to the main circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flexible circuit board is made more rigid to resist tensile and bending forces, then the reliability improves, but the flexibility and ease of connection deteriorates
Solution Approach 1:
The circuit board system is segmented into a rigid circuit board for structural support and a flexible circuit board for adaptive connection, with each serving distinct functional roles. The rigid board provides the necessary mechanical strength while the flexible board maintains adaptability for connection purposes.
Solution Approach 2:
The patent employs a composite structure combining rigid and flexible circuit board materials to achieve both mechanical strength and flexibility. This composite approach allows the system to simultaneously possess the rigidity needed for force resistance and the flexibility required for easy connection and adaptation.
2Reliability
If the coupling pads are increased in size and number to enhance coupling strength, then the reliability improves, but the device complexity increases
Solution Approach 1:
Multiple coupling pads are merged into integrated pad structures that combine multiple functions. The coupling pads are designed to simultaneously provide mechanical attachment, electrical connection, and structural reinforcement, reducing the overall complexity while maintaining strong coupling between the rigid and flexible boards.
Solution Approach 2:
The coupling pads are designed with multi-functionality, serving as attachment points for mechanical bonding, conductive paths for electrical connections, and structural elements for reinforcing the flexible circuit board. This universal design reduces the need for separate components, thereby reducing device complexity.
3Strength
If the flexible circuit board is designed with multiple coupling pads for enhanced attachment, then the strength improves, but the manufacturing precision requirements increase
Solution Approach 1:
The coupling pads are pre-positioned and pre-configured during the manufacturing process with predetermined locations and orientations. This preliminary action ensures that alignment is built into the design from the outset, reducing the precision requirements during final assembly while maintaining strong attachment strength.
Solution Approach 2:
The design incorporates parameter variations in the coupling pads, such as different sizes, shapes, and spacing arrangements, to optimize both attachment strength and manufacturing feasibility. By adjusting these parameters, the design achieves robust coupling without requiring excessive manufacturing precision.
Data Source
AI summary
A battery pack includes: a battery cell; a main circuit board electrically connected to the battery cell and extending in a first direction; and a flexible circuit board extending in the first direction in parallel with the main circuit board and including an external connection terminal located at a position outside the main circuit board, and the main circuit board and the flexible circuit board respectively include first and second coupling pads overlapping each other and coupled to each other.