FFC Battery Interconnect With Integrated Sensing for Compact Modules
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Solution Overview
Problem
The complexity and size of battery modules are increased due to the need for multiple sensing members and fastening units, which complicates the assembly process and poses safety risks, especially in applications like electric vehicles where vibration and impact are factors.
Innovation Solution
An interconnection member with a flexible flat cable (FFC) structure that integrates voltage and temperature sensing, eliminating the need for separate fastening members by using a main cable with branching terminal and connecting parts, allowing for compact installation and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate sensing members and fastening units are used for voltage sensing, temperature sensing, and mechanical fastening, then the sensing and fastening functions are achieved, but the device complexity and overall size increase
Solution Approach 1:
The patent combines voltage sensing, temperature sensing, and mechanical fastening functions into a single integrated interconnection member. The FFC structure with branched terminal parts serves multiple functions: the main cable provides mechanical connection, terminal parts enable voltage sensing, and temperature sensing parts provide thermal monitoring. This merging eliminates the need for separate sensing members and fastening units, reducing assembly complexity while maintaining all required functions.
Solution Approach 2:
The interconnection member is designed as a universal component that performs multiple functions simultaneously. The FFC-based structure can be configured with different numbers and arrangements of terminal parts to accommodate various battery cell configurations. The same basic structure provides electrical connection, voltage sensing, temperature sensing, and mechanical fastening, making it adaptable to different applications without requiring separate specialized components.
2Reliability
If multiple separate components are used for sensing and fastening, then the required functions are achieved, but the overall size of the battery module increases
Solution Approach 1:
By merging voltage sensing, temperature sensing, and fastening functions into one interconnection member, the patent significantly reduces the space required compared to using separate components. The FFC structure with integrated terminal parts eliminates gaps and redundant structures between separate components, allowing compact installation within the battery module while maintaining all safety and sensing functions.
3Reliability
If multiple separate sensing members and fastening units are installed, then the sensing and fastening requirements are met, but the assembly process becomes too complicated
Solution Approach 1:
The integration of multiple functions into a single interconnection member dramatically simplifies the assembly process. Instead of installing separate voltage sensors, temperature sensors, and fastening units, the FFC-based interconnection member can be installed as one component that automatically provides all required functions. The modular FFC structure allows for easy configuration and installation while maintaining comprehensive sensing and control capabilities.
4Reliability
If separate fastening units are used to maintain stable contact under vibration and impact, then the contact stability is achieved, but the device complexity increases
Solution Approach 1:
The patent uses FFC (flexible flat cable) as the base structure for the interconnection member. The inherent flexibility of the FFC allows it to absorb vibration and impact forces while maintaining stable electrical and mechanical contact. This flexible film approach eliminates the need for complex rigid fastening units with multiple fastening elements, as the FFC structure itself provides the necessary contact stability under dynamic conditions through its flexible nature.
Data Source
AI summary
What is discussed is an interconnection member including (a) a main cable made of a flexible flat cable (FFC) including copper wires, (b) terminal parts branched from the main cable and electrically connected to at least one of the copper wires of the main cable, (c) a connecting part formed on one-side end of the main cable, and electrically and mechanically connected to a PCB and (d) at least one temperature sensing part branched from the main cable, wherein the at least one temperature sensing part comprises a first extending part extending from the main cable while sharing at least one copper wire of the copper wires of the main cable and a ceramic thermistor disposed on an end of the first extending part while being electrically connected to the first extending part.