Hybrid Circuit Board Layout for Low-Height Battery Pack Busbars
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Solution Overview
Problem
Existing battery packs face issues with increased height, complex structure, and higher costs due to the use of bolts and separate terminals for connecting busbars to rigid circuit boards, which complicates the assembly and makes it difficult to reduce module height.
Innovation Solution
A hybrid circuit board comprising a rigid and flexible substrate combination, where busbars are connected to the flexible substrate without bolting or tox clinching, incorporating swelling absorption structures to mitigate damage from cell swelling, and integrating components on a reinforced substrate to simplify assembly and reduce height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolts and insert nuts are used to mount the busbar on the rigid circuit board, then the electrical connection is reliable, but the height of the battery pack increases and the structure becomes complicated
Solution Approach 1:
The patent combines the busbar mounting function and swelling absorption function into a single integrated terminal structure. The terminal directly connects the busbar to the circuit board without requiring separate bolts and insert nuts, while simultaneously providing swelling absorption through its flexible design. This merging of functions reduces structural complexity and eliminates multiple fastening components.
Solution Approach 2:
The terminal is designed to perform multiple functions: electrical connection, mechanical fastening, and swelling absorption. By making the terminal multi-functional, the patent eliminates the need for separate components for each function, thereby reducing the overall structure complexity and assembly steps while maintaining reliable electrical connection.
2Reliability
If a separate terminal with swelling-absorption structure is bolted between the rigid circuit board and the battery cell, then the battery cell swelling is absorbed, but the height of the battery pack increases and the structure becomes complicated
Solution Approach 1:
The patent merges the swelling absorption function into the terminal structure itself, eliminating the need for a separate swelling absorption component. The terminal's flexible design allows it to deform and absorb swelling forces directly at the connection point between the busbar and circuit board, reducing structural complexity.
Solution Approach 2:
The terminal is designed as a multi-functional component that simultaneously provides electrical connection, mechanical fastening, and swelling absorption. This universal design eliminates the need for separate components for each function, thereby reducing structural complexity and assembly steps.
3Strength
If the tox clinching process is used for connecting the busbar, then the connection strength is improved, but the manufacturing cost increases and the structure becomes complicated
Solution Approach 1:
The patent replaces the complex tox clinching mechanical process with a simpler terminal-based connection system. The terminal provides strong mechanical and electrical connection through its integrated design, eliminating the need for specialized tox clinching equipment and processes, thereby reducing manufacturing cost and complexity while maintaining connection strength.
4Adaptability or versatility
If multiple separate components (busbar, terminal, bolts, insert nuts) are used for connection, then the functionality is comprehensive, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The patent combines multiple separate components (busbar, terminal, bolts, insert nuts) into an integrated terminal structure that performs all necessary functions. This merging reduces the number of assembly steps and components, thereby improving assembly efficiency and productivity while maintaining functional completeness.
Solution Approach 2:
The terminal is designed as a universal multi-functional component that replaces multiple separate components. It simultaneously provides electrical connection, mechanical fastening, and swelling absorption, eliminating the need for separate assembly steps for each function and thereby improving assembly efficiency.
Data Source
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AI summary
Embodiments of the present disclosure relate to a hybrid circuit board and a battery pack having the same. The battery pack includes: a plurality of battery cells arranged in one direction, each of the battery cells including a positive electrode terminal and a negative electrode terminal; a plurality of busbars electrically connected to the positive electrode terminal or the negative electrode terminal of each of the battery cells; and a hybrid circuit board including a rigid substrate and a flexible substrate that is coupled to the rigid substrate and is electrically connected to the busbars. The rigid substrate is arranged between the busbars and the flexible substrate.