Flexible Circuit Connector for Battery Pack Assembly

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Solution Overview

Problem

Existing methods for electrically connecting electrochemical cells in battery packs are time-consuming, labor-intensive, and often involve high-temperature soldering or welding, which can be costly and challenging for quality control, especially in medical devices requiring sustained power.

Innovation Solution

The use of a flexible circuit with conductors attached via openings, allowing for efficient and automated assembly, minimizing high resistance paths and potential damage to sensitive areas, while enabling defined weld locations and improved durability against shock and vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding nickel conductors directly to electrochemical cells and then soldering/welding to electrical system is used, then electrical connection is achieved, but the process exposes cells to elevated temperatures and requires expensive hand labor

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidelevated temperature exposure to electrochemical cells

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a flexible circuit board as an intermediary component between the electrochemical cells and the electrical system. The conductors are first attached to the flexible circuit board at defined locations, and then the flexible circuit board is attached to the electrochemical cells. This intermediary approach eliminates direct high-temperature exposure of the cells during conductor attachment while maintaining reliable electrical connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the electrical connection process into two distinct stages: (1) attaching conductors to the flexible circuit board at defined locations, and (2) attaching the flexible circuit board to the electrochemical cells. This segmentation allows the conductor attachment to occur away from the cells, avoiding temperature exposure, while maintaining connection reliability.

Inventive Principle:

Principle #1Segmentation

2Reliability

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly speed and labor efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent performs preliminary action by pre-attaching the conductors to the flexible circuit board before the final assembly with the electrochemical cells. The conductors are positioned and secured at defined locations on the flexible circuit board in advance, which simplifies the final assembly process and eliminates time-consuming hand labor during cell integration.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flexible circuit board serves as a self-integrating component that combines multiple functions: it holds the conductors at defined locations, provides structural support, and enables attachment to the electrochemical cells. This self-service approach eliminates the need for separate operations to position and secure conductors during cell assembly, significantly improving productivity.

Inventive Principle:

Principle #25Self-service

3Reliability

If conventional conductor attachment methods are used, then electrical connection is achieved, but quality control is challenging and expensive

Engineering Contradiction:

Improveelectrical connection qualityVSAvoidquality control difficulty and cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent implements local quality by defining specific attachment locations on the flexible circuit board where conductors are secured. These defined locations ensure consistent, high-quality connections while enabling automated manufacturing processes. The localized attachment points on the flexible circuit board provide precise control over connection quality without requiring expensive hand labor for inspection and adjustment.

Inventive Principle:

Principle #3Local quality

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

This approach streamlines the manufacturing process, enhances quality and reliability, reduces build times, and maintains the integrity of sensitive areas on electrochemical cells, making it suitable for high-demand applications like medical devices.

Implementation Method 1

The conductors may be welded or otherwise attached to an electrochemical cell

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

These and other embodiments minimize the high resistance path through the connector

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Data Source

PatentUS11183724B2Electrochemical cell connector having flexible circuit including plurality of arms with conductor in opening of arms and battery pack containing same

Publication Date: 2021.11.23 TC1 LLC

AI summary

The present disclosure is directed to an electrochemical cell connector for electrically connecting a plurality of electrochemical cells, and to battery packs including the electrochemical cell connector. The electrochemical cell connectors of the present disclosure are fabricated from a flexible circuit. The flexible circuit includes conductors, such as nickel conductors, soldered or otherwise attached thereto via holes or openings in the flexible circuit. These conductors may be welded or otherwise attached to an electrochemical cell, and the electrochemical cell connections made on the flexible circuit. In many embodiments, the conductors may be attached to the flexible circuit using industry standard automated assembly equipment thus streamlining the manufacturing process and improving overall quality of the product.