Battery Module Sensing Unit With Direct FPCB-Busbar Coupling

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Solution Overview

Problem

Existing battery module sensing units have complex structures, require numerous components, and involve costly and time-consuming manufacturing processes, leading to increased volume and cost.

Innovation Solution

A battery module sensing unit with a simplified assembly structure where the FPCB and busbar are directly coupled, overlapping each other, eliminating the need for a conventional sensing plate and using a busbar frame with a receiving portion for the FPCB and a projecting portion for direct contact with the busbar.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional sensing plate and multiple connection components are used to connect the FPCB and busbar, then reliable electrical connection is achieved, but the number of parts increases, manufacturing cost increases, and the volume of the sensing unit increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The busbar frame integrates multiple functions: it provides mechanical support, electrical connection, and positioning for the FPCB. The frame includes a busbar mounting portion for electrical connection and an FPCB receiving portion with positioning protrusions, combining structural and electrical functions into a single component that eliminates the need for separate sensing plates and connection hardware.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar frame serves multiple purposes simultaneously: it acts as a mechanical support structure, an electrical conductor, a positioning element for the FPCB, and a mounting fixture. This multi-functionality reduces the total number of components while maintaining reliable electrical connections and proper assembly alignment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If welding and terminal pressing processes are used to connect the busbar and FPCB, then strong electrical connection is achieved, but manufacturing time increases and production cost increases

Engineering Contradiction:

Improveelectrical connection strengthVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention replaces complex mechanical connection processes (welding and terminal pressing) with a simplified mechanical insertion system. The FPCB is inserted into the busbar frame's receiving portion and secured by positioning protrusions that engage with corresponding features, eliminating the need for thermal or heavy mechanical fastening processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The busbar frame's receiving portion is designed with positioning protrusions that automatically align and secure the FPCB during insertion. The structure self-aligns the components without requiring external alignment tools or complex fastening operations, enabling quick assembly while maintaining connection reliability.

Inventive Principle:

Principle #25Self-service

3Strength

If epoxy application and extended coupling are used to connect the FPCB and sensing plate, then strong mechanical bonding is achieved, but the overall length of the sensing unit increases and the structure becomes more complex

Engineering Contradiction:

Improvemechanical bonding strengthVSAvoidsensing unit volume

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The busbar frame combines the mechanical support and electrical connection functions into a single integrated structure. The FPCB receiving portion with positioning protrusions provides both mechanical support and electrical contact in one component, eliminating the need for separate sensing plates and epoxy bonding layers, thereby reducing the overall volume.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If multiple separate components are used in the sensing unit, then functional requirements are met, but manufacturing cost increases and assembly complexity increases

Engineering Contradiction:

Improvefunctional requirements fulfillmentVSAvoidmanufacturing simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The busbar frame merges mechanical support, electrical connection, and positioning functions into a single component. This integration reduces the number of parts that need to be manufactured, inventoried, and assembled, while still fulfilling all necessary functional requirements for voltage sensing and mechanical support.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar frame is designed as a multi-functional component that simultaneously provides structural support, electrical conduction, and precise positioning for the FPCB. This universality reduces assembly complexity and manufacturing steps while maintaining all required functions for battery voltage monitoring.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12573675B2Battery module sensing unit and manufacturing method thereof

Publication Date: 2026.03.10 LG ENERGY SOLUTION LTD

AI summary

The present invention relates to a battery module sensing unit having a simple structure, more particularly a battery module sensing unit including a sensing member (120), an FPCB (100) including the sensing member (120), a busbar frame (300) connected to the FPCB (100), and a busbar (200) coupled to the busbar frame (300), wherein the FPCB (100) and the busbar (200) are directly coupled to each other while overlapping each other.