Dual-Sided PCB Bus Layout for High-Density Battery Modules
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Solution Overview
Problem
Conventional aircraft battery systems are bulky and inefficient in terms of space utilization, consuming valuable fuselage space and increasing weight due to the need for large structures to enclose and support batteries, which limits cargo and personnel capacity.
Innovation Solution
A compact battery module design utilizing a dual-sided printed circuit board (PCB) bus that allows for the placement of battery cell terminals on both sides of the PCB, reducing the number of required PCBs and enabling a more compact, modular, and efficient packaging of battery cells, with a positive common bus for aggregation of positive terminal voltage and a negative common bus for negative terminal voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional single-sided PCB bus design is used, then battery cell connectivity is achieved, but battery module volume increases and cell density decreases
Solution Approach 1:
The patent transitions from a single-sided PCB bus design to a dual-sided PCB bus design, utilizing both faces of the PCB to connect battery cells. This dimensional change allows battery cells to be arranged more compactly in three-dimensional space, reducing the overall battery module volume while increasing the number of cells that can be packed into the same space.
Solution Approach 2:
The patent combines the functions of two separate single-sided PCBs into a single dual-sided PCB. By merging the connectivity functions of both sides onto one board, the design eliminates redundant structures and reduces the total volume required for battery cell interconnections, thereby improving cell density.
2Quantity of substance
If more battery cells are packed in given volume, then energy capacity increases, but thermal management complexity increases
Solution Approach 1:
The dual-sided PCB bus structure serves multiple functions simultaneously: it provides electrical connectivity for battery cells while also acting as a thermal conduction pathway. The PCB's dual-sided design allows for integrated thermal management where the same structure that reduces volume also facilitates heat dissipation, reducing the need for separate complex thermal management systems.
3Quantity of substance
If dual-sided PCB bus is used, then battery cell density increases, but manufacturing complexity increases
Solution Approach 1:
The dual-sided PCB bus is designed with modular connector segments that can be independently manufactured and assembled. Each side of the PCB can be configured with standardized connector patterns, allowing for simplified manufacturing processes despite the increased functional complexity. The segmentation approach enables parallel manufacturing of different PCB sections.
Data Source
AI summary
A compact battery module incorporating a dual-sided printed circuit board (PCB) bus is presented. The present disclosure provides for an increase in battery cells per given volume by utilizing both sides of a PCB bus. In one embodiment, a PCB bus can be configured to receive battery cell terminals on both sides of the PCB via one or more connectors, thereby providing for a more compact battery module that is simpler and eliminates interconnections. By having a single PCB disposed between battery cells having both the positive negative terminals on one side, a more compact design can be realized with fewer printed circuit boards and lower weight.