Battery Pack PCBA Sensing Layout to Cut Wiring Complexity
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Solution Overview
Problem
Conventional energy storage systems require significant manual assembly and use extensive wire and connectors for voltage and temperature sensing, leading to increased complexity and costs.
Innovation Solution
The implementation of a printed circuit board assembly (PCBA) configuration with a metal strip that connects to battery cells to provide temperature or voltage data directly to a battery management unit, reducing assembly time and complexity while eliminating the need for expensive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire harness and connectors are used to connect BMU to thermistors and voltage connectors, then voltage and temperature sensing can be achieved, but assembly complexity and manual labor increase significantly
Solution Approach 1:
The patent combines multiple sensing functions (voltage sensing and temperature sensing) into a single integrated PCBA that directly contacts the battery cell terminals. This eliminates the need for separate wire harnesses, connectors, and thermistor attachments, thereby reducing assembly complexity while maintaining sensing capability.
Solution Approach 2:
The PCBA serves multiple functions simultaneously: it acts as both a voltage sensing electrode and a temperature sensing substrate. By integrating both sensing capabilities into one component that contacts the battery cell, the system achieves multi-functionality without requiring separate dedicated components for each sensing type.
2Loss of information
If extensive wire and connectors are used for sensing, then complete voltage and temperature data can be collected, but manufacturing costs and assembly time increase
Solution Approach 1:
The PCBA integrates both voltage and temperature sensing functions into a single component that is directly mounted on the battery cell. This consolidation reduces the number of assembly steps from multiple separate component installations to a single mounting operation, significantly reducing assembly time while maintaining complete data collection capability.
3Reliability
If traditional wire harness and connector systems are used, then reliable electrical connections are established, but the number of components and materials required increases
Solution Approach 1:
The patent merges multiple separate components (wire harness, connectors, thermistors, voltage sensing elements) into a single integrated PCBA. This consolidation maintains reliable electrical connections for both voltage and temperature sensing while dramatically reducing the total number of components and materials required in the system.
Data Source
AI summary
The present disclosure provides a battery pack configured for use with an energy storage system. For example, the battery pack can comprise a battery cell and a printed circuit board assembly comprising a metal strip configured to connect to the battery cell and provide at least one of temperature or voltage data of the battery cell to a battery management unit operably coupled to the printed circuit board assembly.