Flexible Battery Interconnector for Multi-Surface Cell Monitoring
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Solution Overview
Problem
Conventional battery modules require complex and time-consuming installation processes for wire harnesses, leading to increased component count and manufacturing costs, and inadequate static control of power output, which fails to meet dynamic power demands of electrical consumers.
Innovation Solution
A battery module design utilizing a flexible interconnector with a strip-shaped flexible printed circuit (FPC) that wraps around aligned battery cells with differently oriented surfaces, providing electrical and thermal connections to a cell supervision circuit (CSC) without the need for multiple wire harnesses, thereby reducing component count and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire harnesses are used for connecting battery cells to cell supervision circuit, then electrical connections can be established, but the component count increases and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple wire harnesses into a single flexible printed circuit board (FPCB) that integrates all necessary electrical connections between battery cells and the cell supervision circuit. This merging of multiple separate components into one unified interconnector reduces the overall component count while maintaining reliable electrical connections across all battery cells.
Solution Approach 2:
The flexible interconnector serves multiple functions simultaneously: it provides electrical connections for voltage monitoring, current measurement, and thermal management signaling all through a single component. This multi-functional design eliminates the need for separate wire harnesses for each function, thereby reducing component complexity while ensuring comprehensive monitoring capabilities.
2Reliability
If multiple wire harnesses are installed for battery cell connections, then all electrical connections can be made, but the installation process becomes time-consuming
Solution Approach 1:
By consolidating multiple wire harnesses into a single flexible interconnector with integrated circuitry, the patent enables all electrical connections to be established through one installation process rather than multiple separate installations. This significantly reduces the time required for assembly while ensuring that all necessary electrical connections are completed.
Solution Approach 2:
The flexible interconnector is pre-configured with printed circuit traces and connection points during manufacturing, so that upon installation, all electrical connections are already prepared and ready to be connected. This preliminary preparation eliminates the need for time-consuming on-site wiring and connection work during the installation phase.
3Reliability
If conventional wire harnesses are used, then electrical connections can be established, but manufacturing costs increase
Solution Approach 1:
The patent merges multiple separate wire harnesses into a single flexible printed circuit board, which can be manufactured using standardized PCB fabrication processes. This consolidation reduces the total number of components that need to be sourced, inventoried, and assembled, thereby lowering manufacturing costs while maintaining stable electrical connections through the integrated design.
Solution Approach 2:
The patent replaces the mechanical wire harness assembly system with a printed circuit board system where electrical connections are created through standardized PCB trace routing and soldering processes. This substitution enables automated manufacturing with higher precision and lower labor costs, reducing overall manufacturing expenses while ensuring reliable electrical connections.
4Reliability
If rigid connectors are used for battery cell connections, then stable connections can be achieved, but adaptability to differently oriented surfaces is reduced
Solution Approach 1:
The patent employs a flexible printed circuit board as the interconnector, which can bend and conform to the surfaces of battery cells with different orientations. This flexibility allows the interconnector to adapt to various cell arrangements and surface angles while maintaining stable electrical connections through consistent contact pressure and alignment, overcoming the limitation of rigid connectors.
Solution Approach 2:
The flexible interconnector introduces dynamic adaptability to the connection system, allowing it to adjust its shape and position to match differently oriented battery cell surfaces. This dynamic characteristic enables the same interconnector design to work with various cell configurations and orientations, providing both stability and versatility.
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 flexible interconnector enables efficient and cost-effective assembly of battery modules by simplifying the connection process, reducing component count, and enhancing dynamic power management by allowing for flexible contact with variously oriented battery cell surfaces, improving the battery module's ability to meet dynamic power demands.
Implementation Method 1
A flexible interconnector includes a strip-shaped flexible printed circuit (FPC) with a plurality of thermally and/or electrically conducting lines
Implementation Method 2
A flexible interconnector includes a strip-shaped flexible printed circuit (FPC) with a plurality of thermally and/or electrically conducting lines
Data Source
AI summary
A battery module includes: a plurality of aligned battery cells having differently-oriented surfaces; a cell supervision circuit (CSC) configured to receive signals corresponding to the voltage and/or temperature of at least one of the battery cells; and a flexible interconnector comprising a strip-shaped flexible printed circuit (FPC). The FPC includes a first insulating main surface, a second insulating main surface opposite the first insulating main surface, and a plurality of thermally and/or electrically conducting lines between the first insulating main surface and the second insulating main surface. Each of the conducting lines has a contact portion exposed by a contact aperture in the first insulating main surface and/or in the second insulating main surface and a connecting portion for connection to the CSC, and the flexible interconnector wraps around the battery cells such that the contact portions contact the differently-oriented surfaces of the battery cells.