Battery Pack PCB Stacking for Higher Energy Density
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Solution Overview
Problem
The existing battery packs face challenges in achieving improved durability and inner space efficiency, which leads to a decrease in energy density due to the large volume occupied by the battery management unit, particularly the printed circuit board.
Innovation Solution
The battery pack is designed with a battery management unit that includes at least two printed circuit boards arranged such that their broad surfaces face each other and are electrically connected. This configuration, along with a pack housing and a fixing unit, allows for efficient use of inner space and secure fixation of the printed circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large printed circuit board is used in the battery management unit to accommodate various control elements, then charging and discharging control capability is improved, but the volume occupied by the battery management unit increases, reducing energy density
Solution Approach 1:
The battery management unit is divided into multiple printed circuit boards instead of using a single large board. Each PCB can be independently designed and optimized, allowing control elements to be distributed across multiple smaller boards that can be arranged more efficiently in the limited space, thus maintaining control capability while reducing overall volume occupation
Solution Approach 2:
The patent transitions from a single-plane PCB layout to a three-dimensional stacked arrangement of multiple PCBs. By utilizing the vertical dimension and stacking PCBs in layers with electrical connections between them, the design accommodates various control elements without increasing the horizontal footprint, thereby reducing the volume occupied in the battery pack while maintaining full control functionality
2Power
If multiple battery cells are electrically connected in series or parallel to provide required output and capacity, then power and capacity requirements are met, but the complexity of the battery pack structure increases
Solution Approach 1:
The battery management unit with multiple PCBs is designed to universally manage various battery cell configurations (series, parallel, or combination). The modular PCB architecture can adapt to different connection topologies without requiring fundamental redesign, simplifying the overall system while meeting diverse power and capacity requirements through flexible electrical connection management
Data Source
AI summary
Disclosed is a battery pack with improved durability and inner space efficiency to increase energy density. The battery pack includes a plurality of battery cells; a battery management unit configured to manage charging and discharging of the plurality of battery cells and including at least two printed circuit boards electrically connected to each other and arranged such that such that surfaces of the at least two printed circuit boards face each other; and an electrically insulating pack housing having an inner space in which the plurality of battery cells are accommodated and having a fixing unit being configured to fix the at least two printed circuit boards.