Battery Module Sensing Assembly With Hybrid PCB Bonding
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Solution Overview
Problem
The existing sensing assemblies for battery modules require manual labor for assembly, leading to high production costs and potential errors due to the need for skilled workers to fold and attach flexible printed circuit board (FPCB) members, which increases the usage of expensive FPCB materials.
Innovation Solution
A sensing assembly using a combination of rigid printed circuit boards (RPCB) and FPCB, where electrical bonding is achieved through soldering, electroconductive films, or ultrasonic/laser welding, allowing for automated assembly and reduced FPCB usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If FPCB members are used to connect battery cells in sensing assemblies, then flexibility and space utilization are improved, but manual assembly is required which increases production cost and complexity
Solution Approach 1:
The sensing assembly is divided into modular components: battery cells with integrated sensing electrodes, FPCB members for electrical connection, and housing structures. This segmentation allows each component to be manufactured independently and assembled systematically, reducing manual labor complexity while maintaining space efficiency
Solution Approach 2:
The FPCB members serve multiple functions: they provide electrical connectivity between battery cells, act as structural support elements, and enable sensing functionality through integrated electrodes. This multi-functionality reduces the number of separate components needed, simplifying assembly while optimizing space utilization in the battery pack
2Manufacturing precision
If skilled workers are used to fold and attach FPCB members, then assembly precision is improved, but production cost increases due to labor requirements
Solution Approach 1:
FPCB members are pre-formed with folded configurations and pre-attached with adhesive layers before final assembly. The sensing electrodes are pre-positioned and secured on the FPCB members, allowing these components to be prepared in advance and then quickly installed in the battery assembly, reducing the need for skilled manual folding and attachment during production
Solution Approach 2:
Adhesive layers serve as intermediaries between the FPCB members and the battery cell housing, providing precise positioning and secure attachment without requiring complex manual alignment. The adhesive acts as a mediator that simplifies the bonding process while maintaining assembly precision
3Reliability
If more FPCB material is used to ensure proper assembly, then reliability is improved, but material cost and waste increase
Solution Approach 1:
FPCB members are designed with varying thicknesses and material properties in different regions: thicker sections provide structural support and reliability where needed, while thinner sections reduce material usage in areas requiring flexibility. This localized optimization ensures adequate reliability while minimizing overall material consumption and waste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, reduces production costs, and enhances assembly efficiency by enabling automated assembly and minimizing errors, while allowing the use of FPCB in smaller amounts, thus improving space utilization and reducing material waste.
Implementation Method 1
a bonding portion formed using an electroconductive film
Implementation Method 2
a welding portion formed using ultrasonic welding or laser welding
Implementation Method 3
a welding portion formed using ultrasonic welding or laser welding
Data Source
AI summary
Provided are a sensing assembly and a battery module including the same, having improved economical efficiency in such a manner that a relatively expensive flexible printed circuit board is used in a smaller amount by allowing a relatively inexpensive rigid printed circuit board to replace a portion of the flexible printed circuit board used for a conventional sensing assembly.