Folded Sensing Substrate in Battery Packs for Protected Cell Monitoring
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Solution Overview
Problem
Existing battery packs lack effective mechanisms for acquiring state information, such as temperature, voltage, and current, from battery cells while preventing damage to sensing devices from impact with the battery cells.
Innovation Solution
A battery pack design incorporating a sensing unit with a one-sided circuit board sensing substrate, where the sensing device is placed on the top surface opposite to the battery cell, and the sensing terminal is connected on the bottom surface, allowing them to cross each other, thereby preventing impact damage and enabling stable soldering and state information acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensing device is placed close to the battery cell for accurate measurement, then measurement precision is improved, but the sensing device is at risk of impact damage from the battery cell
Solution Approach 1:
The sensing substrate is folded back underneath the battery cell assembly, changing the spatial dimension from a direct top-surface mounting to a bottom-surface mounting through folding. This allows the sensing device to remain close to the battery cell for accurate measurement while being positioned on the opposite side to avoid impact damage.
Solution Approach 2:
The sensing substrate acts as an intermediary carrier that can be folded back to position the sensing device in a safe location while maintaining measurement capability. The substrate mediates between the need for close proximity measurement and the need for physical protection.
2Ease of manufacture
If a traditional double-sided circuit board is used for the sensing substrate, then ease of manufacture is improved, but device complexity increases due to the need for sensing terminal crossing
Solution Approach 1:
Instead of routing sensing terminals through the thickness of a double-sided board (z-dimension), the substrate is folded back in the plane (x-y dimension), allowing terminals to cross naturally without complex through-hole routing or multilayer design.
Solution Approach 2:
The conventional approach of having terminals pass through the board thickness is inverted by folding the entire substrate back, so that what would be a complex through-board connection becomes a simple surface connection on the folded structure.
3Object-affected harmful factors
If the sensing substrate is folded back underneath the battery cell, then protection from impact is improved, but the structure becomes more complex
Solution Approach 1:
The sensing substrate serves multiple functions: it carries the sensing device, provides structural support, enables signal routing, and through its folded configuration, provides physical protection. This multi-functionality reduces the need for additional protective structures.
Solution Approach 2:
The protective function is merged with the structural carrier function by folding the sensing substrate itself to form a protective configuration, rather than adding a separate protective element. The substrate becomes both the carrier and the protector.
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
This design effectively collects state information from battery cells without risking damage to the sensing devices and simplifies the manufacturing process by using a one-sided circuit board, reducing costs and enhancing reliability.
Implementation Method 1
at least one sensing device formed on the sensing substrate at a first position for acquiring state information of the battery cell
Implementation Method 2
a sensing terminal connected to the sensing substrate at a second position different from the first position and connected to the battery cell side to acquire the state information
Data Source
Figure 1
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AI summary
Provided is a battery pack. The battery pack includes at least one battery cell and at least one sensing unit for acquiring state information of the battery cell, the sensing unit including sensing substrates which extend in parallel in a first direction and include a first position where at least one sensing device is formed, and at least one sensing terminal connected to the sensing substrate at a second position different from the first position and connected to the battery cell side to acquire the state information, where the sensing substrate and the sensing terminal i) overlap each other at the first and second positions, and ii) extend to cross each other so that upper and lower positions are reversed in the second direction in which the sensing substrate and the sensing terminal overlap each other at the first and second positions. Provided is the battery pack in which the sensing substrate provided as a one-sided circuit board is applied to form the sensing unit for collecting state information of the battery cell, and top and the bottom surface of the sensing substrate is laminated with the sensing device and the sensing terminal that extend to cross each other.