Battery Pack Substrate Split Layout for Easier Pouch Cell Assembly
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Solution Overview
Problem
The assembly of battery packs using pouch type cells with flexible printed circuit boards (FPCBs) results in increased material costs and reduced component mounting area due to the extended length of the FPCBs, especially when the assembly positions of the external substrate and FPCB are far apart.
Innovation Solution
A battery pack design featuring a terrace extension from the battery cell with a first substrate connected to the battery cell and a detachable second substrate, where the connector is mounted on the first substrate, allowing for flexible positioning and reduced interference with the external substrate, along with a support member to prevent deformation and a protective film with a marking line for easier installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the FPCB is extended to connect the battery cell and external substrate when assembly positions are far apart, then the electrical connection is maintained, but material costs increase and component mounting area is reduced
Solution Approach 1:
The substrate is divided into two separate substrates: a first substrate connected to the battery cell and a second substrate serving as the external substrate. This segmentation eliminates the need for a long FPCB extension, reducing material costs while maintaining electrical connection through a connector that interfaces between the two substrates.
Solution Approach 2:
A connector acts as an intermediary component between the first substrate (attached to battery cell) and the second substrate (external substrate). This intermediary enables electrical connection without requiring a long flexible circuit board, thus reducing material usage while preserving connectivity.
2Reliability
If the FPCB is extended to connect the battery cell and external substrate when assembly positions are far apart, then the electrical connection is maintained, but the component mounting area of the external substrate is reduced
Solution Approach 1:
By segmenting the substrate into a first substrate (for battery cell connection) and a second substrate (for component mounting), the component mounting area on the external substrate is maximized. The first substrate handles the connection function, allowing the second substrate to be positioned optimally for component placement without being constrained by a long FPCB extension.
3Stability of the object's composition
If a rigid structure is used to prevent deformation of the substrate, then structural stability is improved, but flexibility and ease of assembly are reduced
Solution Approach 1:
The support member is designed with elastic deformability, allowing it to flex during assembly to accommodate the substrate and then maintain structural stability once assembled. This dynamic property enables easy assembly while ensuring structural integrity during operation.
Solution Approach 2:
The support member's material properties are optimized to exhibit elastic deformability within a specific range, allowing temporary deformation during assembly followed by recovery to maintain structural stability. This parameter optimization balances flexibility for assembly with rigidity for structural support.
Data Source
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AI summary
The present disclosure relates a battery pack that is easy to assemble and can reduce an interference region with an external substrate (S). The present disclosure provides a battery pack including a battery cell (100), a terrace (200) extending from the battery cell (100), a first substrate (300) disposed on the terrace (200) and connected to the battery cell (100), a connector (400) mounted on the first substrate (300), and a second substrate (500) detachably coupled to the connector (400) and extending to the outside of the battery cell (100).