Folded Flexible Circuit Member for Long Battery Monitoring
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Solution Overview
Problem
The manufacturing of longer flexible circuit boards for battery systems is challenging due to processing limitations and high production costs, making it difficult to effectively monitor voltage and temperature in multi-row or larger battery units.
Innovation Solution
A flexible circuit member is created by folding an integrally-formed flexible circuit board with an extension unit, comprising a first body portion, a second body portion, and a stacking portion, which increases in length after unfolding, allowing for efficient information collection from longer battery units with reduced manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple FPCs are used for signal collection in multi-row or longer battery units, then the information collection capability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple FPC functions into a single integrated flexible circuit board with extension units that can be folded to span across multiple battery units. This merging approach eliminates the need for multiple separate FPCs and their associated connectors, thereby improving information collection capability while reducing device complexity and the number of components required
Solution Approach 2:
The patent introduces a spatial dimension by folding the flexible circuit board into extension units that can be stacked and extended along the length of the battery pack. This dimensional transformation allows a single FPC to cover longer distances and multiple battery units without increasing planar area, effectively improving adaptability while maintaining simplicity
2Adaptability or versatility
If multiple FPCs are used for signal collection in multi-row or longer battery units, then the information collection capability is improved, but the production cost increases
Solution Approach 1:
The patent combines multiple FPC functions into a single integrated flexible circuit board with extension units that can be folded to span across multiple battery units. This merging approach eliminates the need for multiple separate FPCs and their associated connectors, thereby improving information collection capability while reducing device complexity and the number of components required
Solution Approach 2:
The flexible circuit board is designed as a universal component that can serve multiple battery units through its extension units. The same FPC structure can be configured for different battery pack sizes and arrangements by adjusting the folding of extension units, reducing the need for custom-designed FPCs for different applications and thereby lowering production costs
3Adaptability or versatility
If a longer flexible circuit board is manufactured to monitor longer battery units, then the information collection capability is improved, but the manufacturing difficulty increases due to processing limitations
Solution Approach 1:
The flexible circuit board is segmented into standard-length sections connected by foldable extension units. Each section can be manufactured using standard processing equipment within existing length limitations, and the extension units are folded during assembly to achieve the required total length. This segmentation approach enables information collection over longer distances while avoiding the manufacturing challenges of producing single-piece ultra-long FPCs
Solution Approach 2:
The extension units are pre-configured in a folded state during FPC manufacturing, and the folding is finalized during battery pack assembly. This preliminary action allows the FPC to be manufactured in standard lengths using conventional equipment, while the final extended configuration is achieved through controlled folding at the system integration stage, thereby reducing manufacturing difficulty
Data Source
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Figure 5
AI summary
A flexible circuit member (1) includes an extension unit having a first body portion (11), a second body portion (12), and a stacking portion (13) connected between the first and second body portions (11, 12). The stacking portion (13) has at least two layers due to the folding processing. A first end of the extension unit in a long-axis direction (X) is an end portion of the first body portion (11) that is not connected to the stacking portion (13). A second end of the extension unit in the long-axis direction (X) is an end portion of the second body portion (12) that is not connected to the stacking portion (13). A conductive wire harness for electrical signal transmission extends from the first end to the second end. After the stacking portion (13) is unfolded, a distance between the first and second ends in the long-axis direction (X) decreases.