Flexible Circuit Buffer for Secondary Battery Mechanical Shock Protection
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Solution Overview
Problem
Secondary batteries face reliability issues due to mechanical and electrical characteristics, particularly during charging and discharging cycles, which can lead to short-circuits and operational failures under external shocks or impacts.
Innovation Solution
A secondary battery design incorporating a pouch-type case with a flexible circuit portion that acts as a buffer between the rigid circuit portion and the case, featuring a bypass circuit pattern for rapid charging and protection against mechanical stress, along with a protective device to prevent overcharging and over-discharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid circuit portion is used to ensure electrical connection stability, then electrical reliability is improved, but mechanical robustness deteriorates due to susceptibility to damage from external shocks and impacts
Solution Approach 1:
The circuit portion is designed to be flexible rather than rigid, allowing it to dynamically adapt to mechanical stresses. The flexible circuit board can bend and deform under external shocks without breaking, maintaining electrical connectivity while absorbing mechanical energy.
Solution Approach 2:
A flexible circuit board is used instead of a rigid circuit board to provide both electrical connection functionality and mechanical flexibility. The flexible nature of the thin film circuit allows it to withstand external shocks and impacts while maintaining stable electrical connections between terminals.
2Strength
If a flexible circuit portion is used to improve mechanical robustness, then resistance to external shocks is improved, but electrical connection stability deteriorates
Solution Approach 1:
The flexible circuit board is designed with proper structural support and routing to maintain electrical stability while providing mechanical flexibility. The circuit traces are configured to maintain consistent electrical pathways even when the flexible substrate deforms under external stress.
Solution Approach 2:
The flexible circuit board acts as an intermediary between the rigid battery terminals and the external environment. It transmits electrical connections while absorbing mechanical shocks, protecting the rigid terminals from direct impact damage.
3Reliability
If the circuit portion is made rigid to ensure stable electrical connections, then electrical reliability is improved, but device complexity increases due to additional protective measures required
Solution Approach 1:
The circuit portion is designed to be flexible rather than rigid, allowing it to dynamically adapt to mechanical stresses. The flexible circuit board can bend and deform under external shocks without breaking, maintaining electrical connectivity while absorbing mechanical energy.
Solution Approach 2:
A flexible circuit board is used instead of a rigid circuit board to provide both electrical connection functionality and mechanical flexibility. The flexible nature of the thin film circuit allows it to withstand external shocks and impacts while maintaining stable electrical connections between terminals.
Data Source
AI summary
A secondary battery includes: an electrode assembly including a positive electrode plate, a negative electrode plate, and a separator between the positive electrode plate and the negative electrode plate; a case accommodating the electrode assembly; a negative electrode lead and a positive electrode lead extending from the case and being respectively connected to the negative electrode plate and the positive electrode plate of the electrode assembly; a rigid circuit portion including a plurality of connection portions and an external connection terminal, the connection portions being respectively connected to the negative electrode lead and the positive electrode lead; and a flexible circuit portion including a bypass circuit pattern connecting the connection portions and the external connection terminal of the rigid circuit portion to each other, the flexible circuit portion being curved between a first side surface of the case and the rigid circuit portion.