Battery Pack FPC-FFC Wiring Layout for Lighter BMM Interconnection
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Solution Overview
Problem
Existing battery packs for electric vehicles face inefficiencies due to complex and costly cable arrangements for connecting battery management modules (BMMs) and sensor devices, leading to increased weight, complexity, and reduced space efficiency.
Innovation Solution
A flexible conductor arrangement using a combination of flexible printed circuits (FPCs) and flexible flat cables (FFCs) that branch and route conductor lines to interconnect BMMs, sensor devices, and battery cells, reducing the need for rigid connections and cable clips, thereby minimizing wiring and enhancing manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid cable arrangements are used to connect BMMs and sensor devices, then reliable electrical connections are achieved, but the battery pack weight increases and space efficiency decreases
Solution Approach 1:
The patent replaces traditional rigid cables with flexible printed circuit boards (FPCs) and flat flexible cables (FFCs) that have thin film structures. These flexible conductors maintain reliable electrical connections while significantly reducing the weight and thickness of the wiring system, directly addressing the contradiction between connection reliability and weight reduction.
Solution Approach 2:
The patent substitutes the mechanical cable connection system with an integrated FPC/FFC system that combines electrical conduction and mechanical support functions. This substitution eliminates the need for separate cable clips and mechanical fasteners, reducing overall weight while maintaining connection reliability through the flexible circuit board's inherent adhesion and routing capabilities.
2Stability of the object's composition
If complex cable arrangements with multiple cable clips are used, then secure mechanical fixation is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the functions of electrical conduction, mechanical support, and structural routing into a single integrated FPC/FFC system. By combining these previously separate functions into one component, the wiring system complexity is reduced while maintaining mechanical fixation stability, as the flexible circuits are designed to work with simplified mounting structures.
Solution Approach 2:
The flexible printed circuit boards and flat flexible cables serve multiple functions simultaneously: they provide electrical connections, act as structural elements for routing, and enable flexible positioning of BMMs and sensor devices. This multi-functionality reduces the number of separate components needed, thereby simplifying the overall wiring system while maintaining secure mechanical fixation.
3Reliability
If extensive wiring is used to connect all battery components, then complete electrical interconnection is achieved, but space efficiency and manufacturability decrease
Solution Approach 1:
The patent segments the wiring system into modular FPC and FFC components that can be independently manufactured and then integrated. This segmentation allows for standardized production of circuit board portions that can be systematically assembled with battery cells and BMMs, improving manufacturability while maintaining complete electrical interconnection through the modular design.
Solution Approach 2:
The patent replaces the traditional mechanical cable assembly process with an integrated FPC/FFC system that simplifies the manufacturing workflow. The flexible circuits can be pre-assembled with BMMs and sensor devices in a more straightforward manner, reducing assembly steps and improving manufacturability while ensuring complete electrical interconnection across all battery components.
Data Source
AI summary
A battery pack includes: a plurality of battery cells; a battery management module (BMM); a plurality of sensor devices and/or a plurality of current collector devices; and a flexible conductor arrangement including a plurality of conductor lines, a flexible printed circuit (FPC), and a plurality of flexible flat cables (FFCs) connected to the FPC. The conductor lines are routed along the FPC and branch into the plurality of FFCs, and each of the conductor lines electrically interconnects the BMM with one of the sensor devices, one of the current collector devices, and/or one of the battery cells via the FPC and via one of the FFCs.