Battery Module Flexible PCB Routing in Overlapped Control Board Space
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Solution Overview
Problem
As the capacity of a battery pack increases, the number of battery cells per module also increases, leading to a higher number of wirings that need to be efficiently accommodated within a limited space on the battery module.
Innovation Solution
The battery module incorporates a flexible printed board with wiring that is strategically positioned between the control board and battery cells, utilizing the space efficiently by having portions of the wiring overlap with the control board and plate member, and includes a connector portion that connects to the control board, allowing for effective electrical connection and space optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of battery cells per module is increased to increase capacity, then the battery pack capacity is improved, but the number of wirings increases leading to space utilization problems
Solution Approach 1:
The flexible printed board is positioned such that portions of its wiring are located between the control board and the battery cells in regions where they overlap when viewed from the first side. This nesting arrangement allows the wiring to utilize the vertical space within the overlapping region, effectively hiding the wiring within the existing structural footprint and avoiding additional horizontal space requirements.
Solution Approach 2:
The patent transitions from a two-dimensional planar arrangement of wirings to a three-dimensional configuration by positioning portions of the flexible printed board's wiring between the control board and battery cells in the vertical dimension. This allows wirings to be disposed in the Z-direction (thickness direction) within overlapping regions, effectively utilizing vertical space that would otherwise be unused.
2Adaptability or versatility
If more wirings are disposed on the battery module to handle increased capacity, then the electrical connection capability is improved, but the limited space on the battery module becomes insufficient
Solution Approach 1:
The flexible printed board's wiring is nested within the overlapping region between the control board and battery cells, allowing multiple wirings to be disposed within the vertical space of the existing structure. This enables increased electrical connection capability without proportionally increasing the horizontal footprint.
Solution Approach 2:
A flexible printed board is used instead of rigid wiring structures, allowing the wiring to be bent and positioned in three-dimensional space. This flexibility enables the wiring to navigate through and between components, utilizing vertical and lateral spaces that would be inaccessible to rigid wiring, thereby increasing connection capability within limited space.
Data Source
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AI summary
A battery module includes: a plurality of battery cells (100) arranged in a first direction; a plate member (400) provided on a first side of the plurality of battery cells (100); and a flexible printed board (500) and a control board (900) each provided on the plate member (400), wherein the flexible printed board (500) has a wiring (500B) electrically connected to the control board (900), and at least a portion of the wiring (500B) of the flexible printed board (500) is located between the control board (900) and at least one of the battery cells (100) at a region overlapping with the control board (900) when viewed from the first side.