Battery Pack PCB Integration for EMI Reduction
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Solution Overview
Problem
Existing battery packs, particularly lead acid and lithium-ion types, face issues with reliability due to electromagnetic interference, mechanical stress, and complex wiring, leading to reduced lifespan and increased maintenance needs, while also being heavy and environmentally hazardous.
Innovation Solution
A battery pack design utilizing printed circuit board portions with signal traces connected directly to terminals, eliminating separate wiring and incorporating a battery pack condition management unit, which reduces electromagnetic interference and allows for compact, efficient, and automated manufacturing, enhancing reliability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate wiring is used to connect voltage measurement and balancing means to battery cells, then the battery pack can be assembled with conventional methods, but electromagnetic interference increases and reliability decreases
Solution Approach 1:
The patent merges the separate wiring connections into an integrated printed circuit board structure. The PCB portions are directly connected to the battery cell terminals, eliminating the need for separate wire connections. This integration reduces electromagnetic interference while maintaining ease of manufacture through standardized PCB fabrication processes.
2Ease of manufacture
If complex wiring with separate connections is used for voltage measurement and balancing, then conventional assembly methods can be applied, but manufacturing labor increases and soldering quality issues arise
Solution Approach 1:
Multiple separate wiring functions are merged into a single printed circuit board structure. The PCB portions perform both voltage measurement and balancing functions through integrated circuitry, eliminating the need for separate wire connections and reducing manufacturing labor.
Solution Approach 2:
The patent replaces the mechanical wiring and soldering system with a printed circuit board system. This substitution eliminates manual wiring and soldering operations, reducing manufacturing labor and improving consistency through automated PCB fabrication processes.
3Device complexity
If lead acid batteries are used, then the battery pack is heavy, but the structure is simple and well-established
Solution Approach 1:
The patent changes the fundamental parameter of battery chemistry from lead acid to lithium-ion. This parameter change reduces the weight of the battery pack while the integrated PCB design maintains structural simplicity through consolidation of components.
4Weight of moving object
If lithium-ion batteries are used, then the battery pack weight is reduced, but overcharge and temperature monitoring become critical safety requirements
Solution Approach 1:
The patent merges the monitoring functions into the integrated PCB structure. The PCB portions are directly connected to battery cell terminals, enabling voltage measurement and balancing functions in a compact, unified design that reduces overall system complexity despite the added safety monitoring requirements.
Data Source
AI summary
The invention relates to a battery pack, comprising a plurality of battery cells arranged consecutively. Each of said battery cells comprise a positive and a negative terminal on opposite sides of the battery cell, the battery cells being electrically connected in series with each other, wherein the terminals of the plurality of battery cells are arranged on two opposite sides of the battery pack such that positive and negative terminals of the consecutive battery cells are on both sides of the battery pack by turns next to each other. The battery pack further comprises a first and a second printed circuit board portion arranged on said two opposite sides of the battery pack, respectively. The first and the second printed circuit board portions comprise connection interfaces arranged next to the terminals of the battery cells. The first and the second printed circuit board portions comprise signal traces connected to the terminals of the battery cells via the connection interfaces. The battery pack further comprises a third printed circuit board portion arranged next to the battery cells and extending between the first and the second printed circuit board portions, such that the battery cells are located in a channel defined by the first, the second and the third printed circuit board portions. The third printed circuit board portion comprises a battery pack condition management unit connected to the signal traces of the first and the second printed circuit board portion.