FPC Connection Module With Slits for Battery Terminal Misalignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In battery blocks for electric automobiles and hybrid vehicles, dimensional tolerance due to manufacturing and mounting errors causes positional shifts between bus bars and electrode terminals, making it difficult to mount connection modules, especially when the number of battery cells is large.
Innovation Solution
A connection module with a flexible printed circuit board and connecting members, featuring tolerance-absorbing slits and deflection portions that allow for adjustable placement to conform to positional shifts, reducing the need for multiple bus bar-equipped flexible printed circuit boards and simplifying the configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of battery cells is increased to form a battery block, then the energy storage capacity is improved, but the accumulation of manufacturing dimensional errors and mounting errors causes large overall dimensional tolerance, making it difficult to mount the connection module
Solution Approach 1:
The flexible printed circuit board is divided into multiple segments by introducing slits, creating a segmented structure that can independently deform. This segmentation allows each segment to accommodate local dimensional variations in battery cells, preventing the accumulation of errors across the entire connection module.
Solution Approach 2:
The flexible printed circuit board utilizes changes in physical parameters (flexibility and deformability) to adapt to dimensional tolerances. By making the circuit board flexible rather than rigid, it can dynamically adjust its shape to match the actual positions of electrode terminals, compensating for manufacturing and mounting errors.
2Device complexity
If traditional rigid bus bar-equipped flexible printed circuit boards are used, then the connection structure is simple, but the positional shift between bus bars and electrode terminals due to dimensional tolerance makes mounting difficult
Solution Approach 1:
The connection module transitions from a rigid structure to a dynamic, flexible structure. The flexible printed circuit board can deform and adapt its shape during mounting, allowing the bus bars to automatically align with electrode terminals despite positional shifts, thereby improving mounting workability without increasing structural complexity.
Solution Approach 2:
The patent employs a flexible printed circuit board as a thin, deformable film that can bend and conform to dimensional variations. This flexible structure allows the connection module to adapt to manufacturing tolerances and mounting errors, making the mounting process easier while maintaining a simple overall configuration.
3Reliability
If two separate bus bar-equipped flexible printed circuit boards are used to connect both terminal rows, then the connection coverage is complete, but the configuration complexity and number of components increase
Solution Approach 1:
The patent merges the function of two separate bus bar-equipped flexible printed circuit boards into a single integrated flexible printed circuit board. By incorporating both first and second bus bar rows on one board, the design reduces the total number of components while maintaining complete connection coverage for both terminal rows, thereby simplifying the overall configuration.
Solution Approach 2:
The single flexible printed circuit board is designed to perform multiple functions: it contains both first bus bar rows and second bus bar rows to connect both terminal rows of battery cells. This multi-functional design eliminates the need for separate connection boards, reducing component count while ensuring comprehensive electrical connection coverage.
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
Improves mounting workability by accommodating dimensional errors and positional shifts, ensuring reliable connection between battery cells without increasing the module's size or complexity.
Implementation Method 1
the pair of deflection portions can be deflected in a direction in which the two connecting member placement portions that are adjacent to each other with the tolerance absorbing portion interposed therebetween move toward and away from each other
Data Source
AI summary
A connection module includes an FPC and a plurality of bus bars. The plurality of bus bars constitute a first bus bar row disposed along one long side of the FPC, and a second bus bar row disposed along the other long side of the FPC. The FPC includes tolerance absorbing portions each including a slit and a pair of deflection portions disposed with the slit interposed therebetween, and is divided into a plurality of wiring portion by the tolerance absorbing portions. The pair of deflection portions constituting the first tolerance absorbing portion can be deflected in a direction in which the two wiring portions that are adjacent to each other with the first tolerance absorbing portion interposed therebetween move toward and away from each other. The same description also applies to the second tolerance absorbing portion.