FPCB-Mounted Battery Module Connector for Vibration-Stable Packaging
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Solution Overview
Problem
The existing connection structure between flexible printed circuit boards (FPCBs) and connectors in battery modules is inefficient, leading to reduced productivity and increased defect rates due to contact failures under vibration or impact. Additionally, the installation of connectors increases the volume of the battery module, resulting in a loss of energy density.
Innovation Solution
A battery module design that includes a bus bar frame assembly and a FPCB assembly, where the connector is mounted on the second FPCB, which is biased to create space for the connector, minimizing volume increase and improving energy density. The connector is directly mounted to the FPCB using pins, simplifying the installation process and reducing the risk of contact failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector is installed to sense voltage or connect components in a battery module, then the electrical connection reliability is improved, but the volume of the battery module increases
Solution Approach 1:
The connector is nested within the space formed by the biased arrangement of electrode leads. The electrode leads are positioned asymmetrically to create a void space that accommodates the connector, allowing the connector to be housed within the existing structural envelope rather than adding external volume.
Solution Approach 2:
The electrode leads are arranged in a biased configuration along the longitudinal direction, creating space in a different dimensional plane (transverse space) that can accommodate the connector without increasing the overall module volume in any primary dimension.
2Reliability
If terminals are compressed individually to the FPCB to establish electrical connection, then the electrical connection is established, but the productivity deteriorates
Solution Approach 1:
Multiple terminal compression operations are merged into a single integrated process. The FPCB is compressed as a whole unit to the connector, establishing all electrical connections simultaneously rather than requiring individual terminal compression for each contact point.
Solution Approach 2:
The FPCB is pre-positioned and pre-compressed to the connector in a preliminary assembly step, establishing all electrical connections before final module assembly. This preliminary action eliminates the need for subsequent individual terminal compression operations.
3Reliability
If terminals are compressed to the FPCB to establish electrical connection, then the electrical connection is made, but the contact failure risk increases under vibration or impact
Solution Approach 1:
Multiple individual terminal connections are merged into a single integrated FPCB-to-connector compression structure. This unified compression distributes mechanical stress across all contact points simultaneously, preventing localized failure under vibration or impact that would occur with individually compressed terminals.
Solution Approach 2:
The FPCB compression structure is designed to accommodate and cushion vibrational and impact forces before they can cause contact failure. The flexible nature of the FPCB and the distributed compression structure provide inherent cushioning that protects the electrical connections from shock and vibration.
Data Source
AI summary
Disclosed is a battery module, which includes a cell stack formed by stacking a plurality of battery cells; a bus bar frame assembly including a bus bar frame configured to cover one longitudinal end and the other longitudinal end of the cell stack and a plurality of bus bars fixed on the bus bar frame and electrically connected to the battery cells; and a FPCB assembly including a first FPCB extending along a longitudinal direction of the cell stack to cover at least a portion of an upper surface of the cell stack, a second FPCB extending from one longitudinal end of the first FPCB and electrically connected to the bus bars, and a connector having a connector pin inserted into a pin insert hole formed in the second FPCB.