Flexible Conductive Module Layout for Compact Battery Packs
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Solution Overview
Problem
The existing battery packs for electric and hybrid vehicles face challenges in reducing size to improve mountability and energy density, with the conductive module being a significant contributor to the overall size and complexity.
Innovation Solution
The battery pack design incorporates a conductive module with a flexible printed circuit board and bus bars to connect battery cells and a monitoring unit, eliminating the need for separate connectors and wires, thereby reducing the physical size and complexity of the conductive system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack uses conventional conductive modules with separate connectors and wires to connect battery cells and monitoring units, then reliable electrical connections are achieved, but the physical size and structural complexity of the battery pack increase
Solution Approach 1:
The patent combines multiple separate conductive components (connectors and wires) into a single integrated flexible printed circuit board. The FPC integrates both connection functions (power and signal) and monitoring functions into one unified structure, eliminating the need for separate connectors and wires while maintaining reliable electrical connections between battery cells and the monitoring unit
Solution Approach 2:
The flexible printed circuit board serves multiple functions simultaneously: it acts as both a connector and a wire, provides power transmission paths, and includes monitoring electrode terminals for battery status monitoring. This multi-functional integration reduces the overall number of components and simplifies the conductive module structure
2Ease of manufacture
If the battery pack uses conventional conductive modules with multiple separate components, then ease of assembly is maintained, but the overall battery pack size increases reducing energy density
Solution Approach 1:
By merging multiple separate conductive components into a single flexible printed circuit board, the patent significantly reduces the overall volume occupied by the conductive module. The FPC's compact and flexible structure allows it to fit within the battery pack with minimal space, thereby reducing the battery pack's overall size and improving energy density
Solution Approach 2:
The patent utilizes a flexible printed circuit board, which is a thin and flexible conductive structure. This allows the conductive module to be made compact and adaptable to the battery pack's internal space constraints, significantly reducing the volume required for electrical connections and monitoring components
Data Source
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AI summary
A conductive module (1) includes a conductive part (20) is provided with a flat laminated body (30) formed of a plurality of conductors (31) and an insulator (32) having flexibility. The conductive part (20) includes a first conductor (31A) that is configured to electrically connect the battery cells (BC) to a battery monitoring unit (40), and a second conductor (31B) that is configured to electrically connect the battery monitoring unit (40) to electrical equipment (51), as the conductors (31), and includes a first connector (21) that is configured to be fitted and connected to a counterpart connector of the battery monitoring unit (40) and is configured to electrically connect the first conductor (31A) and the second conductor (31B) to the battery monitoring unit (40), and a second connector (22) that is configured to be fitted and connected to a counterpart connector disposed on the electrical connection box (50) side and is configured to electrically connect the second conductor (31B) to the electrical equipment (51).