Flexible Printed Circuit Battery Sensor Tolerance Compensation
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Solution Overview
Problem
Existing sensor apparatuses for battery systems face challenges in accommodating production-related and mechanical tolerances, leading to inconsistent connections between sensor elements and battery cells, which can affect accurate monitoring of state variables.
Innovation Solution
A flexible printed circuit board is used as an electrically and thermally conductive connecting element, formed in an elastic manner to compensate for tolerances, with a spring element that presses the sensor element against the battery cell, ensuring consistent contact and tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid connecting element is used to connect the sensor element to the electronic unit, then the structural stability is improved, but the ability to compensate for production-related and mechanical tolerances deteriorates
Solution Approach 1:
The connecting element is designed as a flexible printed circuit board (FPC) with elastic properties, allowing it to bend and deform elastically to accommodate tolerances in mounting positions and movements, while maintaining electrical and thermal conduction functionality
Solution Approach 2:
The connecting element incorporates a spring element that provides dynamic elastic deformation capability, enabling the system to adapt to varying distances and positions between the sensor element and electronic unit while maintaining stable electrical connection
2Adaptability or versatility
If the connecting element is made flexible to compensate for tolerances, then the adaptability is improved, but the structural stability and connection reliability deteriorates
Solution Approach 1:
The flexible printed circuit board uses a plastic carrier (such as polyimide, Mylar, nylon, or polyester film) that provides both flexibility for tolerance compensation and sufficient mechanical strength to maintain reliable electrical and thermal connections
Solution Approach 2:
The connecting element is formed with a curved or z-shaped geometry that enhances its elastic deformation capability while maintaining structural integrity, allowing it to absorb mechanical stresses and movements without compromising connection reliability
3Measurement precision
If the sensor element is pressed onto the battery cell with high force to ensure contact, then the measurement precision is improved, but the risk of damaging the battery cell or sensor element increases
Solution Approach 1:
The spring element is designed with optimized material properties and geometric dimensions to provide a controlled contact force that ensures reliable electrical and thermal contact between the sensor element and battery cell terminal while remaining below the threshold that would cause mechanical damage
Solution Approach 2:
The elastic connecting element acts as a cushioning mechanism that absorbs excess mechanical force, preventing direct transmission of high contact forces to the battery cell and sensor element while maintaining sufficient pressure for accurate measurements
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 flexible printed circuit board with a spring element ensures reliable and precise monitoring of battery cell state variables by maintaining contact despite mechanical and production-related tolerances, reducing interference and improving measurement accuracy.
Implementation Method 1
the flexible printed circuit board is formed, at least longitudinally, in an elastic manner
Implementation Method 2
The flexible printed circuit board is preferably formed in such a way that a spring force can be generated by the geometric shape of the printed circuit board so that the sensor element can be brought into contact with the battery cell
Implementation Method 3
at least one electrically and/or thermally conductive connecting element connected to the sensor element so that the sensor element can be connected to the battery cell and to an electronic unit
Implementation Method 4
at least one electrically and/or thermally conductive connecting element connected to the sensor element
Data Source
AI summary
A sensor apparatus (10) for monitoring at least one battery cell (20) of a battery system (100), having a sensor element (11) for detecting at least one state variable of the battery cell (20), at least one electrically and/or thermally conductive connecting element (12) connected to the sensor element (11) so that the sensor element can be connected to the battery cell (20) and to an electronic unit (30) of the battery system (100), wherein the connecting element (12) is formed as a flexible printed circuit board (12).