Flexible PCB Sensing Assembly With Integrated Fuse Leg
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Solution Overview
Problem
Existing sensing assemblies for battery modules are prone to damage from assembly steps and external forces, increase weight and manufacturing costs due to rigid components, and require complex assembly processes.
Innovation Solution
A sensing assembly using a combination of rigid and flexible printed circuit boards with a fuse-integrated sensing leg, where the flexible board reduces weight and simplifies assembly, and the fuse prevents damage from external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal sensing leg with rigid structure is used, then the sensing leg has sufficient strength, but it is prone to damage from assembly steps and external forces
Solution Approach 1:
The patent changes the material parameter of the sensing leg from rigid metal to flexible printed circuit board material. This parameter change allows the sensing leg to maintain sufficient strength while gaining flexibility to resist damage from assembly steps and external forces through elastic deformation rather than brittle failure.
Solution Approach 2:
The patent replaces the rigid metal sensing leg with a flexible printed circuit board structure. This flexible film structure provides both the necessary electrical conductivity and the mechanical flexibility to withstand assembly processes and external forces without damage, resolving the contradiction between strength and damage resistance.
2Stability of the object's composition
If a rigid printed circuit board and metal sensing leg are used, then the assembly is structurally stable, but the weight increases
Solution Approach 1:
The patent replaces heavy rigid metal components with flexible printed circuit board materials. This substitution maintains the necessary structural stability for electrical connections while significantly reducing the weight of the sensing assembly, resolving the contradiction between structural stability and weight reduction.
3Reliability
If a separate fuse component is added, then the sensing leg is protected from overcurrent, but the component assembly process becomes complex
Solution Approach 1:
The patent merges the fuse function directly into the sensing leg structure by forming the fuse as an integrated part of the flexible printed circuit board. This integration eliminates the need for separate fuse components and simplifies the assembly process while maintaining overcurrent protection functionality, resolving the contradiction between reliability and assembly complexity.
Solution Approach 2:
The sensing leg structure is designed to perform multiple functions: electrical sensing, mechanical flexibility, and overcurrent protection through the integrated fuse. This multi-functionality eliminates the need for separate dedicated fuse components, reducing assembly complexity while maintaining protective functionality.
4Reliability
If a separate fuse component is added, then overcurrent protection is provided, but the manufacturing cost increases
Solution Approach 1:
The patent combines the fuse function with the sensing leg into a single integrated flexible printed circuit board structure. This merging eliminates the need for separate fuse components, reducing part count, assembly steps, and manufacturing costs while maintaining overcurrent protection capability.
Solution Approach 2:
The integrated sensing leg structure provides multiple functions including voltage sensing and overcurrent protection through its built-in fuse. This multi-functional design reduces the total number of components required, simplifying manufacturing and reducing costs while maintaining necessary protective functions.
Data Source
AI summary
The present invention relates to a sensing assembly and a battery module that may have a relatively low weight, simplify a component assembly process, reduce manufacturing cost, and prevent a sensing leg from being damaged due to an assembly step or an external force. The sensing assembly may include a first substrate having at least one first terminal and at least one second terminal provided on one surface and formed of a rigid printed circuit board, a second substrate including at least one sensing line electrically connected to the first terminal and formed of a flexible printed circuit board, and a sensing leg having one end electrically connected to the second terminal and including a fuse part that is disconnected when an excessive current flows.