Cylindrical Battery Pack FPC Routing to Reduce Bus Bar Interference
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Solution Overview
Problem
Conventional battery packs with cylindrical batteries face complexity in routing structures due to the need to route bus bars and voltage detection lines while minimizing interference, which complicates the configuration and increases costs.
Innovation Solution
A battery pack design featuring cylindrical batteries with bus bars connected to electrodes and a flexible printed wiring board with a belt-like main body routed along the outer circumferential surfaces of the batteries, including branch portions connected to the bus bars, simplifies the routing structure by allowing for a wider main body and reduced interference with bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bus bars are fixed to electrodes with conventional routing, then electrical connection is achieved, but the routing structure becomes complex and interferes with voltage detection lines
Solution Approach 1:
The flexible printed wiring board transitions from a planar two-dimensional layout to a three-dimensional configuration by routing along the outer circumferential surfaces of cylindrical batteries. This dimensional change allows the board to wrap around batteries, creating spatial separation between power transmission paths (bus bars) and signal detection paths (voltage detection lines), thereby eliminating interference while simplifying the overall routing structure.
Solution Approach 2:
The flexible printed wiring board serves as an intermediary carrier that integrates both bus bar connections and voltage detection line routing. By mounting the board on the outer circumferential surfaces of batteries, it mediates between the electrodes and external circuitry, providing a unified structure that handles both power and signal transmissions without mutual interference.
2Device complexity
If the flexible printed wiring board is routed along outer circumferential surfaces, then the main body can be wider and routing is simplified, but the battery pack width increases
Solution Approach 1:
Instead of expanding the battery pack width to accommodate a wider flexible printed wiring board, the solution routes the board along the outer circumferential surfaces of cylindrical batteries in a three-dimensional configuration. This utilizes the vertical and radial dimensions of the cylindrical battery arrangement, allowing the board to wrap around batteries and achieve sufficient width for routing without increasing the horizontal footprint of the battery pack.
Solution Approach 2:
The flexible printed wiring board is nested within the spatial arrangement of cylindrical batteries by routing along their outer circumferential surfaces. The board effectively uses the existing cylindrical geometry and spacing between batteries as a guide, nesting its path within the natural contours of the battery assembly rather than requiring additional external space.
Data Source
AI summary
A battery pack includes a plurality of batteries having a cylindrical shape, arranged with outer circumferential surfaces of the batteries facing each other, and each of the batteries including electrodes on both ends in an axial direction thereof, a plurality of bus bars fixed to the electrodes, and a flexible printed wiring board including a plurality of conductors connected to the bus bars. The flexible printed wiring board includes a belt-like main body routed along the outer circumferential surfaces of the batteries, and branch portions projecting from the main body and connected to the bus bars.