Flexible Circuit Board Layout for Seismic-Resistant Battery Modules
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Solution Overview
Problem
The existing battery modules face challenges in miniaturization due to the limited routing and design of flexible circuit boards, which result in increased size to accommodate the projecting connecting portions, compromising seismic resistance and space efficiency.
Innovation Solution
A flexible circuit board design with a narrow connecting portion and a wider main body, featuring a longitudinal extending portion that projects and extends in the longitudinal direction, allowing for space-saving while maintaining seismic resistance, and incorporating joint portions with lower breaking strength to facilitate attachment and prevent breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flexible circuit board uses a conventional design with connecting portions projecting in the width direction, then seismic resistance is ensured, but the case body size increases in the width direction
Solution Approach 1:
The connecting portion of the flexible circuit board is designed to extend in the longitudinal direction (first direction) rather than projecting in the width direction (second direction). This dimensional reorientation allows the connecting portion to achieve the necessary length for seismic resistance while containing the width increase within acceptable limits, thus resolving the contradiction between reliability and compactness.
Solution Approach 2:
The flexible circuit board employs an asymmetric design where the connecting portion has different dimensional characteristics compared to the main body. The connecting portion extends predominantly in the longitudinal direction with controlled width, creating an asymmetric layout that optimizes both seismic resistance and space utilization.
2Reliability
If the flexible circuit board is designed to bend with a margin in length for seismic resistance, then connection reliability under vibration is improved, but the routing space requirement increases
Solution Approach 1:
The bending margin for seismic resistance is oriented primarily in the longitudinal direction rather than requiring additional width. This allows the flexible circuit board to accommodate vibration-induced bending while maintaining a compact width profile, effectively resolving the contradiction between connection reliability and routing space.
3Area of stationary object
If the connecting portion is made narrow to save space, then the module size is reduced, but the flexibility and seismic resistance may be compromised
Solution Approach 1:
The connecting portion employs asymmetric dimensional design where the width is controlled to be narrow for space savings, while the length in the longitudinal direction is sufficient to provide the necessary flexibility and bending margin for seismic resistance. This asymmetric approach resolves the contradiction between compactness and reliability.
Solution Approach 2:
The design compensates for the narrow width by extending the connecting portion in the longitudinal direction, transferring the flexibility requirement from the width dimension to the length dimension. This resolves the contradiction by maintaining seismic resistance through longitudinal extension while keeping the module width compact.
Data Source
AI summary
Provided is a wiring material which is advantageous for space saving while ensuring seismic resistance of a flexible circuit board. A wiring material 7 including a flexible circuit board 10 in which a plurality of batteries 3A to 3L arranged in one direction is connected to one another via a bus bar 20 and an arrangement direction of the batteries 3A to 3L is a longitudinal direction of the flexible circuit board 10, includes: a narrow connecting portion 18 connected to the bus bar 20; and a main body 68 that is connected to the connecting portion 18 and includes a portion wider than the connecting portion 18. The connecting portion 18 is configured to have a longitudinal extending portion 18a that projects from the main body 68 in the longitudinal direction and extends in the longitudinal direction.