FPCB-Mounted Battery Module Connector for Compact Cell Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing connection structure between flexible printed circuit boards (FPCBs) and connectors in battery modules is inefficient, leading to high defect rates and increased volume, which affects productivity and energy density.
Innovation Solution
A battery module design featuring a bus bar frame assembly and FPCB assembly with a connector mounted on a second FPCB, utilizing a pin insert hole and stiffener to secure the connector, which minimizes volume increase and enhances electrical connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal is compressed to the FPCB and inserted into the connector, then electrical connection is achieved, but productivity deteriorates due to individual compression processes and defect rate increases due to contact failure risks
Solution Approach 1:
The patent merges the terminal and FPCB into a single integrated structure where the terminal is pre-mounted on the FPCB as a unified component. This eliminates the separate compression process, allowing the entire FPCB with pre-mounted terminals to be directly inserted into the connector, thereby improving both productivity and connection reliability
Solution Approach 2:
The terminals are pre-mounted and fixed on the FPCB before the FPCB is installed in the battery module. This preliminary action of mounting terminals during FPCB manufacturing eliminates the need for individual compression operations during assembly, streamlining the production process and reducing defect rates
2Reliability
If a connector is installed to sense voltage of each battery cell, then electrical connection is achieved, but volume of the battery module increases
Solution Approach 1:
The FPCB is configured to extend in the longitudinal direction of the battery module, utilizing the length dimension rather than occupying additional width or height. This allows the connector to be integrated along the existing longitudinal axis of the module, minimizing volume increase while maintaining voltage sensing capability
Solution Approach 2:
The FPCB serves multiple functions: it provides structural support, carries multiple terminals for voltage sensing of different battery cells, and acts as the connection medium to the connector. This multi-functionality eliminates the need for separate components, reducing overall volume while maintaining sensing capability
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 covering first and second opposite longitudinal ends of the cell stack and a plurality of bus bars fixed to 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 and covering 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.