Flexible PCB Battery Pack Layout for Versatile Cell Stacking
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Solution Overview
Problem
Existing battery pack manufacturing methods using hard printed circuit boards (PCBs) limit the connection structure of battery cells, leading to reduced productivity due to complex nickel wire welding processes and limited stack structure flexibility.
Innovation Solution
A battery pack utilizing a flexible printed circuit board (FPCB) for connecting battery cells, allowing for various stack structures and enabling a more flexible connection process through terminal access, cell connection, and protection circuit integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hard printed circuit board (PCB) is used to connect battery cells, then the connection structure is stable and reliable, but the connection structure is limited by the rigid shape of the PCB
Solution Approach 1:
The patent replaces the hard PCB with a flexible printed circuit board (FPCB) that can bend and adapt to different battery cell arrangements. The FPCB maintains electrical connection functionality while providing the flexibility needed for various stack structures, directly resolving the contradiction between connection stability and structural flexibility.
2Reliability
If a separate protection circuit module is formed with nickel wire welding for each electrode terminal, then the protection function is improved, but the manufacturing process becomes complex and productivity decreases
Solution Approach 1:
The patent integrates the protection circuit directly onto the FPCB, merging the protection circuit module with the connection structure. This eliminates the need for separate nickel wire welding operations for each electrode terminal, as the FPCB provides both connection and protection functions through integrated circuit traces, thereby improving productivity while maintaining protection functionality.
Solution Approach 2:
The FPCB serves multiple functions simultaneously: it provides electrical connection between battery cells, implements protection circuit functionality, and enables flexible structural arrangement. This multi-functionality eliminates the need for separate dedicated protection circuit modules and complex welding operations.
3Adaptability or versatility
If battery cells are connected in arbitrary stack structures, then the design flexibility is improved, but the connection process becomes more complex
Solution Approach 1:
The FPCB's inherent flexibility allows it to accommodate various battery cell stack configurations without requiring complex connection processes. The board can be bent and shaped to match different arrangements, simplifying the connection process while maintaining design flexibility.
Solution Approach 2:
The FPCB provides a dynamic connection solution that can adapt to different stack structures through its bendable nature, allowing the same basic FPCB design to serve multiple configuration requirements without increasing process complexity.
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 use of FPCB enhances the freedom in battery cell connection, enabling diverse stack structures and improved productivity by simplifying the manufacturing process and allowing for miniaturization and weight reduction.
Implementation Method 1
a flexible printed circuit board (FPCB) configured to electrically interconnect the battery cells
Implementation Method 2
the FPCB forms a bending space that is bent and a non-bending space that is not bent according to the stacked state of the battery cells
Data Source
AI summary
Discussed are a battery pack including a cell stack structure using a flexible printed circuit board (FPCB), and more specifically, to a battery pack that forms various stack structures by connecting battery cells through an FPCB and stacking the battery cells in a desired stacked state. The battery pack includes at least two or more stacked battery cells; a flexible printed circuit board (FPCB) configured to electrically interconnect the battery cells; and a battery protection circuit configured to protect the battery cells, wherein the FPCB comprises a cell connection part connecting the battery cells in a predetermined connection state.