Battery Sensing Assembly Using Rigid-Flex PCB for Automated Tab Connection
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Solution Overview
Problem
The existing sensing assemblies for battery modules, which use flexible printed circuit boards (FPCBs) to connect cell tabs, face challenges in automation and high production costs due to manual assembly processes and the need for precise attachment of bent portions, leading to potential errors and excessive use of expensive FPCBs.
Innovation Solution
A sensing assembly utilizing a combination of rigid printed circuit boards (RPCBs) and FPCBs, where electrical bonding is achieved through soldering, electroconductive films, or ultrasonic/laser welding, allowing for automated assembly and reduced FPCB usage, with the RPCB replacing a portion of the FPCB to improve space utilization and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are used to connect cell tabs, then the connection is simple, but the wires are very thin and require separate reinforcement to prevent damage due to vibration
Solution Approach 1:
The connection system is divided into two functional segments: thin flexible wires for electrical connection and a separate rigid reinforcement structure for mechanical strength. This allows each component to optimize its specific function without compromise.
Solution Approach 2:
A reinforcement structure acts as an intermediary element between the thin wires and the external environment, absorbing mechanical stresses and protecting the wires from damage while allowing the wires to maintain their thin profile for flexibility and electrical performance.
2Strength
If reinforcement is added to prevent wire damage, then wire strength is improved, but the thickness increases to at least 3 mm which hinders space utilization
Solution Approach 1:
The system separates the reinforcement function from the wire structure, allowing the reinforcement to be positioned separately or integrated only where needed, thus minimizing the volume occupied while maintaining protective function.
Solution Approach 2:
The reinforcement is positioned in a different spatial dimension or configuration that provides protection without increasing the primary dimensional footprint of the wire assembly, optimizing space utilization in the battery module.
3Volume of moving object
If FPCB is used to connect cell tabs, then space utilization is improved, but the assembly process becomes complex requiring manual attachment of bent portions
Solution Approach 1:
The FPCB is pre-formed with bent portions and connection structures before assembly, allowing these complex features to be created during manufacturing when tools and precision are available, rather than attempting to form them during final assembly.
Solution Approach 2:
Manual mechanical attachment operations are replaced with automated processes such as precision molding, stamping, or robotic assembly techniques that can handle the FPCB bent portions and connection operations automatically.
4Manufacturing precision
If manual assembly is used for FPCB attachment, then assembly precision can be achieved, but productivity decreases and production costs increase
Solution Approach 1:
Manual assembly operations are replaced with automated assembly systems including robotic manipulators, automated insertion machines, or precision conveyance systems that can achieve required precision at high speeds through programmable control and repeatable positioning.
Solution Approach 2:
The design parameters of the FPCB and connection structures are optimized to enable automated handling, such as standardizing dimensions, adding定位 features, or modifying connection geometries to be compatible with automated assembly equipment while maintaining attachment precision.
5Reliability
If more FPCB is used to ensure proper connection, then connection reliability is improved, but production costs increase due to excessive use of expensive FPCB material
Solution Approach 1:
Instead of using excessive FPCB material to ensure connection reliability, the design employs precisely sized and positioned FPCB portions that provide adequate electrical and mechanical connection functions, eliminating unnecessary material usage while maintaining reliability.
Solution Approach 2:
The dimensions, trace widths, and layout parameters of the FPCB are optimized to achieve the minimum required connection reliability with minimal material usage, using precision manufacturing capabilities to ensure consistent performance without over-design.
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
The solution enables easier, automated assembly of the sensing assembly, reduces production costs by minimizing FPCB usage, and enhances the assembly's robustness against assembly errors, improving the overall manufacturing efficiency and space utilization in battery modules.
Implementation Method 1
a first electrical bonding portion formed between one end of the second substrate and the first substrate to electrically bond the sensing line and the first terminal to each other
Implementation Method 2
electrical bonding is achieved through soldering, electroconductive films, or ultrasonic/laser welding
Implementation Method 3
electrical bonding is achieved through soldering, electroconductive films, or ultrasonic/laser welding
Implementation Method 4
electrical bonding is achieved through soldering, electroconductive films, or ultrasonic/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.