Battery FPC-to-PCB Through-Hole Soldering for Reliable Assembly
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Solution Overview
Problem
Existing methods for electrically connecting electronic components in battery systems, such as flexible printed circuits (FPC) and printed circuit boards (PCB), are costly, time-consuming, and prone to errors due to the complexity of plug connectors, hot bar soldering, and crimping contacts.
Innovation Solution
A method involving a flexible printed circuit (FPC) with folded connection portions forming pins and a PCB with through-holes for pin insertion, followed by soldering to conductive platings, eliminating the need for separate connectors and ensuring precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug connectors, hot bar soldering, and crimping contacts are used for electrical connection, then reliable electrical connection is achieved, but manufacturing cost increases and manufacturing time extends
Solution Approach 1:
The patent merges the FPC connection portion directly with the PCB through-hole structure, eliminating the need for separate plug connectors. The FPC connection portion is integrated into the through-hole of the PCB, creating a unified structure that reduces component count and assembly steps while maintaining reliable electrical connection.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components (plug connectors, crimping contacts) from the electrical connection system. By directly soldering the FPC connection portion to the PCB through-hole, the design removes redundant elements that increase cost and complexity.
2Reliability
If plug connectors and crimping contacts are used, then electrical connection is achieved, but device complexity increases due to multiple components
Solution Approach 1:
The FPC connection portion and PCB through-hole are merged into a single integrated structure. The connection portion is directly inserted into and soldered to the through-hole, eliminating the need for separate connectors and reducing structural complexity.
Solution Approach 2:
The through-hole structure serves multiple functions: it provides mechanical support, establishes electrical connection, and guides the FPC connection portion during assembly. This multi-functional design reduces the need for separate specialized components.
3Reliability
If conventional connection methods are used, then electrical connection is established, but manufacturing precision requirements increase due to alignment difficulties
Solution Approach 1:
The FPC connection portion is pre-formed with a shape that fits into the PCB through-hole. This preliminary preparation ensures proper alignment during assembly, reducing the precision requirements during the actual connection process. The connection portion is designed to naturally guide itself into the correct position.
Solution Approach 2:
The through-hole acts as an intermediary structure that facilitates precise alignment between the FPC connection portion and the PCB. The hole provides a physical guide that ensures accurate positioning during assembly, reducing the need for high-precision alignment procedures.
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
Facilitates a low-cost, fast, and reliable electrical connection between FPC and PCB, reducing errors and simplifying the soldering 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
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AI summary
The present disclosure refers to a method for electrically connecting a first electronic component (14) of a battery system (100) with a second electronic component (10) of the battery system (100), the first electronic component (14) having a flexible printed circuit, FPC, (20) wherein the FPC (20) comprises one or more pins (29) formed by folding a connection portion (24) of the FPC (20), one or more conductive strips (26) being disposed on an outer surface of the folded connection portion (24), the second electronic (10) component having a printed circuit board, PCB, (30) wherein the PCB (30) comprises one or more through-holes (32) each adapted to receive one of the pins (29) of the FPC (20), the through-holes (32) extending through the PCB (30) from a first side of the PCB (30) to a second side of the PCB (30), wherein at each of the through-holes (32) an electrically conductive plating (34) is disposed at the second side of the PCB (30) adjacent to the through-hole (32), the method comprising the steps of: a) attaching the FPC (20) to the first side of the PCB (30) such that each of the pins (29) of the FPC (20) is received by one of the through-holes (32) of the PCB (30), b) soldering each of the pins (29) of the FPC (20) to the respective conductive plating (34) of the PCB (30) at the second side of the PCB (30) to electrically interconnect the FPC (20) and the PCB (30).