Folded Flexible Busbar Sampling Layout for Battery Connection Modules
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Solution Overview
Problem
Existing battery connection technologies face challenges in efficiently connecting battery unit arrays while promoting material utilization and reducing production complexity and costs.
Innovation Solution
A battery connection module comprising a plurality of busbars and sampling assemblies, where each sampling assembly includes a first flexible circuit board, an adapting circuit board, and a second flexible circuit board. The first flexible circuit board is constructed by folding sub flexible circuit boards, allowing for increased length and reduced production difficulty, while the adapting circuit board with a wire jumper construction enables different wiring arrangements and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the flexible circuit board is made longer to connect more battery units, then the connectivity and coverage are improved, but the manufacturing difficulty and cost increase significantly
Solution Approach 1:
The flexible circuit board is divided into multiple separate sub-flexible circuit boards, each of which can be manufactured independently at a reasonable size. These segmented boards are then folded and connected to form the complete long-length circuit board structure, enabling connectivity across multiple battery units while maintaining ease of manufacturing for each individual segment.
2Loss of substance
If the flexible circuit board is folded to increase its effective length, then the material utilization ratio is improved, but the production complexity increases
Solution Approach 1:
The circuit board system is segmented into multiple sub-boards that are folded in a coordinated manner. This segmentation allows each sub-board to be manufactured as a simple flat piece with standard dimensions, while the folding arrangement creates the extended effective length. The segmentation reduces production complexity by avoiding the need to manufacture and handle a single large, complex folded structure.
3Adaptability or versatility
If different wiring arrangements are implemented to provide wire jumpers for different output circuit definitions, then the adaptability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The circuit board is divided into multiple sub-boards, each capable of having different wiring arrangements. This segmentation allows different output circuit definitions to be implemented on different segments without requiring complex reconfiguration of the entire circuit board. Each sub-board can be manufactured with its specific wiring pattern independently, simplifying the manufacturing process while maintaining overall system adaptability.
Solution Approach 2:
Different regions or sub-boards of the circuit board system can have different wiring arrangements and circuit definitions tailored to specific local requirements. This local quality approach allows wire jumpers and different output configurations to be implemented only where needed in specific segments, rather than requiring complex universal wiring throughout the entire circuit board, thereby reducing manufacturing complexity and cost.
Data Source
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AI summary
A battery connection module is used to connect a battery unit array, the battery connection module includes a plurality of busbars and a plurality of sampling assemblies, the plurality of busbars are used to connect the battery unit array, each sampling assembly includes a first flexible circuit board, an adapting circuit board and a second flexible circuit board, the first flexible circuit board connects the plurality of busbars, the first flexible circuit board is constituted by folding at least two sub flexible circuit boards, a rear end of the first flexible circuit board includes a turning portion, the turning portion is connected to the adapting circuit board which is positioned in a plane different from a plane where the first flexible circuit board is presented, a front end of the second flexible circuit board is connected to the adapting circuit board, a rear end of the second flexible circuit board includes at least one electrical connector.