Flexible Circuit Assembly for Power Module Cell Tab Connections
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Solution Overview
Problem
Existing power modules for electric vehicles and industrial applications face challenges in efficient energy generation and management due to complex assembly processes and the need for multiple electrical connections, which can increase costs and reduce scalability.
Innovation Solution
The development of a power module with a flexible circuit assembly that integrates electrically conductive cells and thermal sheets, allowing for direct tab-to-tab connections and voltage sensing without the need for busbars, enabling efficient energy management and scalable configurations through various cell layer arrangements and folding options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional busbar connections are used for cell tabs, then electrical connections are established, but the assembly process becomes complex and the number of electrical connections increases
Solution Approach 1:
The patent combines multiple electrical connection functions into a single integrated circuit board that simultaneously connects multiple cell tabs and provides voltage sensing connections. This merging eliminates the need for separate busbars and multiple discrete connections, thereby simplifying the assembly process and reducing overall device complexity.
Solution Approach 2:
The circuit board serves multiple functions simultaneously: it acts as an electrical connector for cell tabs, a voltage sensing pathway, and a structural support element. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly process while maintaining all necessary electrical connections.
2Reliability
If multiple separate electrical connections are used for cell tabs and voltage sensing, then electrical connectivity is achieved, but the number of connections increases and assembly becomes more complex
Solution Approach 1:
The patent merges cell tab connections and voltage sensing connections into a single integrated circuit board structure. The board simultaneously establishes electrical connectivity for current flow and provides dedicated pathways for voltage sensing, thereby maintaining reliable electrical connectivity while reducing the total number of discrete connections and improving assembly reliability.
3Reliability
If conventional rigid circuit boards are used, then electrical connections are stable, but the battery pack height increases and scalability is reduced
Solution Approach 1:
The patent employs a flexible circuit board that can be bent and folded to fit within the compact battery pack structure. This flexible board maintains stable electrical connections through its conductive traces while allowing the battery pack to achieve minimal height and enabling various scalable configurations that rigid boards cannot accommodate.
4Power
If traditional power module configurations are used, then energy generation is achieved, but the assembly process is complex and scalability is limited
Solution Approach 1:
The patent segments the battery pack into modular units where each module uses the integrated flexible circuit board assembly. This segmentation allows for easy scalability by simply adding or removing modules, while maintaining consistent electrical connections and voltage sensing capabilities across the entire pack, thereby enhancing adaptability without compromising power generation.
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 solution simplifies the assembly process, reduces the number of electrical connections, and allows for minimal battery pack height and scalability, enhancing energy efficiency and adaptability in different applications.
Implementation Method 1
The flexible circuit assembly has at least one electrically conductive portion
Implementation Method 2
The flexible circuit assembly may include at least one thermal sheet configured to experience a change in electrical resistance in response to a temperature change
Data Source
AI summary
Configurations for a power module having a flexible circuit assembly and corresponding method. The flexible circuit assembly has at least one electrically conductive portion. A first plurality of cells is placed adjacent to one another to form a first cell layer, the first cell layer being positioned on a first side of the flexible circuit assembly. Each of the first plurality of cells has a respective cell body with at least four respective edges. The first plurality of cells has respective cell tabs, including a respective first tab and a respective second tab both extending from one of the at least four respective edges. The flexible circuit assembly is configured to be aligned with the first cell layer such that a voltage sensing circuit joint is concurrently completed when the respective cell tabs of the first cell layer are joined to respective captured portions of the flexible circuit assembly.