Flexible Printed Circuit Board for Battery Cell Contacting

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Solution Overview

Problem

Conventional battery cell contacting devices are complex to manufacture and fit, and are prone to damage due to movements or swelling of battery cells during charging and discharge cycles.

Innovation Solution

A battery cell contacting device featuring electrically conductive wire contact elements that connect a printed circuit board to cell connectors, allowing for flexible connections that can compensate for cell movements and swelling, and can be easily integrated with sensor elements for temperature monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional battery cell contacting devices are used, then electrical connections can be established, but the device complexity and manufacturing complexity increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidcontacting device complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies flexible printed circuit boards (FPC) instead of rigid PCBs to create a contacting device that can adapt to battery cell movements and swelling. The FPC maintains electrical connections while flexing, resolving the contradiction between connection reliability and device complexity by using a flexible substrate that inherently accommodates dimensional changes without requiring complex compensation mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the mechanical properties of the contacting device by using flexible materials with appropriate elasticity and compliance. The FPC and its supporting structure are designed with specific flexural rigidities and elastic moduli that allow the device to deform within certain limits, maintaining electrical contact while adapting to battery cell dimensional changes, thus reducing overall device complexity.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If rigid contacting structures are used, then manufacturing precision can be maintained, but the structure cannot accommodate battery cell movements and swelling

Engineering Contradiction:

Improvecontacting position precisionVSAvoidaccommodation of cell movements

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent transitions from a static rigid structure to a dynamic flexible structure. The FPC and its supporting elements are designed to deform elastically in response to battery cell movements and swelling, maintaining precise electrical contact throughout the range of motion. This dynamic adaptation preserves manufacturing precision while accommodating dimensional changes.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent incorporates pre-designed flexible elements and compliance features in the contacting device that anticipate and accommodate future battery cell swelling and movements. The FPC is intentionally designed with controlled flexibility to absorb dimensional changes before they can damage the electrical connections, maintaining precision without requiring rigid constraints.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If complex fitting procedures are used, then connection reliability can be improved, but the fitting time and manufacturing cost increase

Engineering Contradiction:

Improvefitting reliabilityVSAvoidfitting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent performs preliminary actions by pre-attaching the FPC to the PCB assembly before final installation in the battery module. The flexible circuit is pre-configured and tested for electrical continuity and mechanical flexibility, ensuring reliable connections are established in advance. This preliminary preparation reduces on-site fitting time and complexity while maintaining high reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the FPC assembly with the PCB and contacting elements into an integrated unit that can be installed as a single component. By combining multiple functions (electrical connection, mechanical support, flexibility compensation) into one integrated assembly, the fitting process is simplified while maintaining connection reliability, reducing both time and manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20230223605A1Battery cell contacting device, and battery module containing such a battery cell contacting device

Publication Date: 2023.07.13 DIEHL AKO STIFTUNG & CO KG

AI summary

A battery cell contacting device for a battery module having a plurality of battery cells electrically coupled to one another via a plurality of cell connectors has a rigid printed circuit board, which, in the region next to the plurality of cell connectors, is arranged over the battery cells and is connected to the plurality of cell connectors via a plurality of contact elements. For the purpose of making fitting easier and more reliable, each of the plurality of contact elements is formed from an electrically conductive wire. The wire, at the first end section of the contact element, is electrically conductively connected to the printed circuit board and, at the opposite, second end section of the contact element, can be electrically conductively connected to the respective cell connector and/or is coupled to a sensor element which can be brought into contact with the respective cell connector.