Battery Module Busbar Assembly With Folded Sensing Circuit Board
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Solution Overview
Problem
The increasing complexity of battery devices leads to connection noise between circuit boards and decreased manufacturing efficiency, particularly in battery modules, due to the need for flexible designs accommodating various shapes and sizes.
Innovation Solution
A busbar assembly with an integrated circuit board featuring overlapping extension portions and a support frame, which includes a sensing terminal for voltage data and a temperature sensor, connected to busbars, and a flexible printed circuit board for efficient signal transmission and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate circuit boards are used for voltage sensing and temperature sensing, then functional separation is achieved, but connection noise occurs and device complexity increases
Solution Approach 1:
The patent combines the voltage sensing circuit board and temperature sensing circuit board into a single integrated circuit board. The voltage sensing extension portion and temperature sensing extension portion are integrated on the same substrate, eliminating the need for separate circuit boards and reducing connection noise while simplifying the overall structure.
2Adaptability or versatility
If circuit boards are designed to fit various battery device shapes, then adaptability is improved, but manufacturing efficiency decreases and material waste increases
Solution Approach 1:
The circuit board employs a flexible design with extension portions that can be bent and folded to adapt to different battery device shapes. The circuit board includes a body portion and multiple extension portions (first extension portion for voltage sensing, second extension portion for temperature sensing) that can be configured in various arrangements, allowing a single standardized board design to fit multiple applications while maintaining manufacturing efficiency.
3Adaptability or versatility
If circuit boards are designed to fit various battery device shapes, then adaptability is improved, but material waste increases due to decreased yield
Solution Approach 1:
The integrated circuit board serves multiple functions: voltage sensing through the first extension portion, temperature sensing through the second extension portion, and structural support. This multi-functional design allows a single standardized circuit board to replace multiple specialized boards, improving manufacturing yield and reducing material waste while maintaining adaptability to different battery configurations.
Data Source
AI summary
A battery module includes a cell stack including a plurality of battery cells, a plurality of busbars electrically connected to the plurality of battery cells, a support frame supporting the plurality of bus bars, and a circuit board electrically connected to the plurality of busbars. The circuit board includes a plurality of extension portions extending in different directions, and at least one overlapping portion in which at least two extension portions, among the plurality of extension portions, overlap.