Flexible Printed Circuit Cell Contact System
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Solution Overview
Problem
Existing cell contact-making systems for electrochemical devices are complex to manufacture and require manual steps, additional processes, and material transitions, making them inefficient and prone to errors.
Innovation Solution
A cell contact-making system utilizing a flexible printed circuit with conductor tracks on an insulating film, where connections are made via welding or soldering directly to cell or terminal connectors, eliminating the need for separate positioning and coating, and allowing for compensation of component tolerances and thermal expansions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cell contact-making systems are used, then connections can be established between signal sources and terminal connectors, but the manufacturing process becomes complex requiring manual steps, additional processes, and material transitions
Solution Approach 1:
The patent combines the signal conductor and insulator into a single integrated flexible printed circuit board structure. The conductor tracks are directly formed on the flexible insulating substrate through printing or deposition processes, eliminating the need for separate positioning and assembly of conductors and insulators. This integration reduces manufacturing complexity while maintaining reliable electrical connections between cell terminals and monitoring systems.
Solution Approach 2:
The flexible printed circuit serves multiple functions simultaneously: it provides electrical conduction through its conductor tracks, electrical insulation through its substrate, mechanical flexibility for positioning adjustment, and structural support for connecting various cell components. This multi-functionality eliminates the need for separate dedicated components for each function, simplifying the overall manufacturing process.
2Stability of the object's composition
If traditional rigid connection methods are used, then stable electrical connections are achieved, but component tolerances and thermal expansions cannot be compensated
Solution Approach 1:
The patent employs a flexible printed circuit board instead of rigid connection structures. The flexible substrate can dynamically adjust its shape and position to accommodate component tolerances and thermal expansions. This dynamic flexibility allows the connection to maintain stable electrical contact despite dimensional changes or misalignments, combining connection stability with adaptability to environmental variations.
3Manufacturing precision
If manual manufacturing steps are used, then precise positioning can be achieved, but productivity decreases and errors increase
Solution Approach 1:
The patent replaces manual mechanical positioning and assembly operations with automated printing or deposition processes to form conductor tracks directly on the flexible substrate. This substitution enables precise positioning through controlled material deposition while allowing high-speed automated manufacturing, thereby improving both positioning precision and productivity simultaneously.
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 system simplifies the manufacturing process, ensures precise and reliable connections, and compensates for component tolerances and thermal expansions, enhancing the reliability and efficiency of electrochemical device operations.
Implementation Method 1
The conductor track is preferably connected to the cell connector by a substance-to-substance bond, for example by welding and/or soldering.
Implementation Method 2
The welding may in particular be performed by an ultrasonic welding method, a friction welding method or a friction stir welding method.
Implementation Method 3
As a result of the flexibility and hence ready deformability of the printed circuit, it is possible for component tolerances to be compensated when the cell contact-making system is assembled, and/or different thermal expansions of the components carrying the signal sources on the one hand and the signal conductor system on the other to be compensated during operation of the electrochemical device.
Data Source
AI summary
A cell contact-making system for an electrochemical device that includes a plurality of electrochemical cells is provided. The cell contact-making system includes a signal conductor system having one or more signal conductors for electrically conductively connecting a signal source to a signal conductor terminal connector or to a monitoring arrangement of the electrochemical device, wherein the signal conductor system includes at least one flexible printed circuit, wherein the flexible printed circuit includes at least one flexible insulating film and at least one conductor track that is arranged on the insulating film.