Flexible Circuit Board with Overlapped Connection Portions
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Solution Overview
Problem
Existing flexible circuit boards used in battery modules face challenges such as material wastage, reduced production yield, and increased risk of damage during assembly due to external forces, leading to inefficiencies in sensing battery cell voltages and potential electrical device damage.
Innovation Solution
A flexible circuit board design featuring a band-shaped central portion with first and second connection circuit portions that overlap and are fixed with adhesive, allowing for improved manufacturing yield and assembly protection, along with third connection circuit portions that directly contact bus bars for efficient voltage sensing and reduced assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a flexible circuit board is used in a battery module to sense battery cell voltages, then the weight of the vehicle is reduced and fuel efficiency is improved, but the circuit board is susceptible to damage from external forces during assembly
Solution Approach 1:
The patent applies beforehand cushioning by positioning the flexible circuit board within the frame structure where it is protected from external forces during assembly. The frame assembly provides a protective environment that cushions the circuit board against damage while maintaining its weight advantages for vehicle application.
2Adaptability or versatility
If the flexible circuit board is designed with multiple connection circuit portions to sense voltages and connect to bus bars, then the functionality for detecting battery cell phenomena is improved, but the complexity of the circuit board structure increases
Solution Approach 1:
The flexible circuit board is segmented into multiple connection circuit portions (first, second, and third connection circuit portions) that can be independently positioned and connected to different bus bars. This segmentation enables versatile voltage sensing across multiple battery cells while maintaining a modular structure that simplifies the overall design and assembly process.
3Volume of moving object
If the second connection circuit portions are folded to form overlapped portions, then the circuit board can be compactly arranged on the frame, but the manufacturing process becomes more complex
Solution Approach 1:
The flexible circuit board utilizes curved folding configurations where the second connection circuit portions are bent into overlapping arrangements. This curvature enables compact space occupation on the frame structure while the folding design itself simplifies manufacturing by allowing the circuit board to be formed into its final configuration through controlled bending rather than complex assembly operations.
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 design minimizes material waste, enhances production yield, and protects the circuit board during assembly, enabling effective voltage sensing and reduced production costs while ensuring reliable electrical connections.
Implementation Method 1
the portions of the second connection circuit portions constituting the first overlapped portion and the second overlapped portion may be closely fixed by an adhesive for providing upward and downward fixing forces
Data Source
AI summary
Provided is a flexible circuit board installed on a frame to which a bus bar is coupled. The flexible circuit board may include a central portion having a band shape, first connection circuit portions formed at both ends of the central portion and disposed to face each other, second connection circuit portions extending from the first connection circuit portions in parallel with the central portion, and third connection circuit portions extending from the first connection circuit portions and the second connection circuit portions and connected to the bus bar. An overlapped may be formed when each of the second connection circuit portions is folded toward one side of each of the first connection circuit portions.