Flexible Printed Circuit Assembly for Automated Battery Module Welding
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Solution Overview
Problem
The existing methods for connecting flexible printed circuits to battery systems are cumbersome, cost-intensive, and often require manual or semi-automatic processes, which are slow and inefficient, particularly in the assembly of battery modules and cell supervision circuits.
Innovation Solution
A fully automated method for connecting a continuous and strip-shaped flexible printed circuit to battery systems, using a tool with a coil holder and guide to unwind, position, and weld the FPC to battery modules and cell supervision circuit boards, eliminating the need for additional holders and allowing for various connection designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or semi-automatic processes are used to connect flexible printed circuits to battery systems, then flexibility in connection design is maintained, but the assembly process becomes slow and inefficient
Solution Approach 1:
The patent replaces manual mechanical operations with an automated welding system. A welding device automatically positions and welds the flexible printed circuit to battery modules and cell supervision circuit boards, eliminating the need for manual handling and significantly improving assembly speed and productivity.
Solution Approach 2:
The flexible printed circuit is designed to be self-positioning through its continuous strip shape, which naturally aligns with the battery modules and circuit boards during the automated welding process, reducing the need for complex positioning mechanisms and additional holders.
2Reliability
If additional holders are used to secure flexible printed circuits during assembly, then connection stability is improved, but device complexity and material costs increase
Solution Approach 1:
The patent removes the additional holders from the assembly process entirely. The continuous strip-shaped flexible printed circuit is designed to be directly welded to the battery modules and circuit boards without requiring any intermediate holding or securing components, thereby simplifying the overall device structure.
Solution Approach 2:
The flexible printed circuit serves multiple functions simultaneously: it provides electrical connections, maintains structural stability through its continuous strip design, and eliminates the need for separate holder components, thereby reducing overall device complexity while maintaining reliability.
3Ease of manufacture
If traditional connection methods are used for battery modules and cell supervision circuits, then assembly process remains simple, but material costs and production time increase
Solution Approach 1:
The patent segments the flexible printed circuit into a continuous strip that can be systematically welded to multiple battery modules and circuit boards in sequence. This segmentation allows for efficient automated processing while maintaining process simplicity, as the same welding procedure is repeated across multiple connection points without requiring complex reconfiguration.
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 method enables a reliable, efficient, and cost-effective assembly process for battery systems by automating the connection of flexible printed circuits to battery modules and cell supervision circuits, improving the assembly process and reducing material costs.
Implementation Method 1
a welding device is used to form a weld connection between a first section of the flexible printed circuit and a first contact portion of a battery module
Data Source
AI summary
A method for connecting a flexible printed circuit (FPC) to a battery module and a cell supervision circuit board (CSCB) is provided. The method includes: providing a coil of a continuous, strip-shaped FPC; unwinding a first section of the FPC from the coil, positioning the first section of the FPC over a first contact portion of the battery module, and welding a conductive structure of the FPC in the first section to the first contact portion of the battery module; unwinding a second section of the FPC from the coil, positioning the second section of the FPC over a contact pad of the CSCB, and welding the conductive structure of the FPC in the second section to the contact pad of the CSCB; and separating the first section and second section of the FPC from the coil of the FPC.