Folded FPC-to-PCB Battery Connection for Faster Assembly
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Solution Overview
Problem
Existing methods for electrically connecting electronic components in battery systems, such as FPCs and PCBs, are costly, error-prone, and time-consuming, particularly due to the complexity of plug connectors and hot bar soldering, and are prone to mechanical issues.
Innovation Solution
A method involving a flexible printed circuit (FPC) with folded connection portions forming pins and conductive strips, and a PCB with through-holes and conductive platings, where the FPC is attached and soldered to the PCB, eliminating the need for separate connectors and ensuring precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug connectors and hot bar soldering are used for electrical connection, then reliable electrical connection is achieved, but manufacturing cost increases and assembly time is extended
Solution Approach 1:
The patent combines the FPC connection portion with the pins to form an integrated structure, eliminating the need for separate plug connectors. The folded connection portion directly provides both mechanical support and electrical contact, merging previously separate components into one unified element that reduces assembly steps and time while maintaining connection reliability
Solution Approach 2:
The patent extracts and eliminates the separate plug connector component from the assembly process. By forming pins directly from the folded FPC connection portion, the design removes the intermediary connector element, simplifying the overall structure and reducing assembly complexity without compromising electrical connection quality
2Reliability
If plug connectors are used for electrical connection, then connection is achieved, but device complexity increases
Solution Approach 1:
The connection portion of the FPC is merged with the pin structure, creating an integrated component that performs both mechanical attachment and electrical connection functions. This consolidation eliminates the need for separate plug connectors and reduces the number of parts, thereby simplifying the overall device structure while maintaining reliable electrical connection
Solution Approach 2:
The folded connection portion serves multiple functions simultaneously: it provides mechanical support, enables precise alignment through the folding geometry, and creates electrical contact through the integrated pin structure. This multi-functionality reduces the need for specialized separate components, simplifying the overall system
3Reliability
If hot bar soldering is used for electrical connection, then reliable solder joint is achieved, but manufacturing cost and assembly time increase
Solution Approach 1:
The connection portion is pre-folded during FPC manufacturing to form the pin structure with predetermined geometry and positioning features. This preliminary formation of the connection structure eliminates the need for complex real-time alignment and soldering operations during assembly, allowing for faster processing while maintaining joint reliability through pre-established precise geometry
4Adaptability or versatility
If separate connectors are used for electrical connection, then connection flexibility is maintained, but manufacturing cost increases
Solution Approach 1:
The FPC connection portion and pin are merged into a single integrated structure, eliminating the need for separate connector components. This reduction in part count directly lowers manufacturing costs associated with producing, inventorying, and assembling multiple separate components, while the integrated design maintains connection flexibility through the inherent flexibility of the FPC material and folded geometry
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 method provides a low-cost, fast, and reliable electrical connection between electronic components, reducing errors and simplifying the assembly process.
Implementation Method 1
soldering each of the pins of the FPC to the respective conductive plating of the PCB at the second side of the PCB to electrically interconnect the FPC and the PCB
Data Source
AI summary
A method for electrically connecting a first electronic component of a battery system with a second electronic component of the battery system is provided. The first electronic component includes a flexible printed circuit (FPC) including: a pin formed by folding a connection portion of the FPC; and a conductive strip on an outer surface of the folded connection portion. The second electronic component includes a printed circuit board (PCB) having a through-hole configured to receive the pin of the FPC and includes an electrically conductive plating adjacent to the through-hole. The method includes: attaching the FPC to a first side of the PCB such that the pin of the FPC is received in the through-hole in the PCB; and soldering the pin of the FPC to the conductive plating on the PCB to electrically interconnect the FPC and the PCB.