Folded Flexible Circuit Board Layout for Dual-Row Battery Sampling
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Solution Overview
Problem
Existing power battery systems with dual-row cell modules use split flexible printed circuit boards (FPCs) that occupy excessive space on the periphery, leading to increased volume and instability in electrical connections, and low splicing utilization rates.
Innovation Solution
A flexible circuit board designed to be folded twice, with a main body and two sampling portions, allowing for compact stacking and reliable electrical connections, reducing peripheral space occupation and improving splicing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If split flexible printed circuit boards are used to sample two groups of cells respectively, then the sampling function is achieved, but the flexible circuit board occupies too much space on the outer side the periphery of the dual-row cell module
Solution Approach 1:
The flexible circuit board is folded into a nested structure where the main body and sampling portions are stacked together. The first sampling portion is folded along the third fold line, the second sampling portion is folded along the fourth fold line, and the main body is folded 180 degrees along the first and second fold lines, creating a compact nested configuration that reduces peripheral space occupation while maintaining all sampling functions.
Solution Approach 2:
The flexible circuit board transitions from a planar two-dimensional layout to a three-dimensional stacked structure through multiple fold lines. By folding the circuit board along predetermined lines, the sampling portions and main body are arranged in different spatial layers, effectively reducing the footprint area while preserving the electrical connection functionality.
2Ease of operation
If the flexible circuit board extends out of the periphery of the dual-row cell module, then connection to cells is achieved, but it occupies space where other components of the battery pack are located
Solution Approach 1:
The flexible circuit board adopts a nested folded structure where the main body and sampling portions are stacked together within the periphery of the dual-row cell module. This nested configuration eliminates the need for the circuit board to extend outward, thereby freeing up space for other battery pack components while maintaining all necessary electrical connections.
3Area of stationary object
If the flexible circuit board is folded multiple times, then space occupation is reduced, but the structural complexity increases
Solution Approach 1:
The flexible circuit board is segmented into distinct functional portions (main body, first sampling portion, second sampling portion) separated by fold lines. Each portion has a specific function and can be independently positioned through folding, which simplifies the overall structure design while achieving compact space occupation. The segmentation allows for modular assembly and maintenance.
Data Source
AI summary
A flexible circuit board (10), an electric connection module and its installation method, and a power battery pack (1000) are provided. The flexible circuit board (10) includes a first sampling portion (12), a second sampling portion (13) and a main body (11). The main body (11) is connected to the first sampling portion (12) and the second sampling portion (13). At least one of the first sampling portion (12) and the second sampling portion (13) is provided with a sampling point. The main body (11) is provided with a sampling signal output terminal (101). In a use state, at least a portion of the main body (11) is stacked with the first sampling portion (12) and the second sampling portion (13).