Hurdle-Shaped FPC Routing for Traction Battery Temperature Sensing
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Solution Overview
Problem
Existing traction batteries for vehicles face challenges in efficiently managing high-voltage components and temperature control, which can affect vehicle performance and battery longevity.
Innovation Solution
A hurdle-shaped flexible printed circuit (FPC) is used in traction batteries, featuring a planar substrate with straight and elbow portions, supporting a circuit that electrically connects temperature sensors to sensing modules across the battery array, facilitating effective thermal management and data communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional rigid printed circuit board is used to connect temperature sensors to sensing modules across the battery array, then electrical connectivity is achieved, but the device complexity and difficulty of installation increase due to the need to route through tight spaces around battery cells
Solution Approach 1:
The patent uses a flexible printed circuit board (FPCB) instead of a rigid PCB. The FPCB can be bent and routed through tight spaces around battery cells to connect temperature sensors on opposite sides of the battery array, achieving electrical connectivity while simplifying installation and reducing device complexity
Solution Approach 2:
The FPCB transitions from a two-dimensional planar layout to a three-dimensional routed configuration by bending and folding through the battery assembly. This allows the circuit to navigate around battery cells and connect components that are spatially separated, solving the routing problem without increasing overall system complexity
2Measurement precision
If rigid circuit boards are used on opposite sides of the battery array, then temperature sensing is enabled, but the thermal management efficiency decreases due to inadequate sensor placement and signal transmission
Solution Approach 1:
The flexible circuit board allows temperature sensors to be positioned in optimal locations on opposite sides of the battery array, enabling better thermal monitoring coverage. The flexibility permits the sensors to be placed close to battery cells without being constrained by rigid board geometry, improving thermal management efficiency
Solution Approach 2:
The FPCB acts as an intermediary that efficiently transmits temperature signals from sensors on opposite sides of the battery array to the sensing module. The flexible nature of the circuit board allows for optimized signal routing that maintains measurement precision while enabling effective thermal management across the entire battery assembly
3Reliability
If complex routing paths are used to connect circuit boards on opposite sides of the battery array, then electrical connectivity is achieved, but the manufacturing precision and assembly difficulty increase
Solution Approach 1:
The flexible printed circuit board is designed with predetermined bend radii and folding patterns that guide assembly. These standardized flexible routing paths maintain manufacturing precision by providing clear assembly instructions while achieving the necessary electrical connectivity between opposite sides of the battery array
Solution Approach 2:
The FPCB is pre-formed with specific bends and folds during manufacturing to match the final installed configuration. This preliminary shaping of the flexible circuit board eliminates the need for complex field assembly operations, reducing assembly difficulty while maintaining precise electrical connections
Data Source
AI summary
A traction battery includes a battery array and a flexible printed circuit (FPC). The FPC including a hurdle-shaped flexible substrate that is planar and has opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion that is joined to the middle portion by a first elbow portion, and a second end portion that is joined to the middle portion by a second elbow portion. The elbow portions are folded relative to the middle portion at first and second folds, respectively, such that the first planar surfaces of the first and second elbows face each other. A circuit is supported by the substrate and electrically connected between circuit boards supported on opposite sides of the battery array.