Integrated PCB-Flex Interconnect Board for Battery Module Monitoring
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Solution Overview
Problem
Existing battery systems face challenges in efficiently monitoring and controlling the state of health and thermal regulation of battery modules, particularly in polyphase electric machines, due to complex interconnects and limited communication methods between battery cells and controllers.
Innovation Solution
The integration of a printed circuit board (PCB) and flexible printed circuit (flex circuit) in the interconnect board assembly, facilitated by reflow surface-mounted technology soldering, enables efficient communication and monitoring through wireless or hardwired links, with conductive busbars connecting to battery cells and supporting electronic components for real-time data transmission and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex interconnects and limited communication methods are used between battery cells and controllers, then device complexity is reduced, but monitoring and control precision deteriorates
Solution Approach 1:
The patent combines the interconnect board and communication interface into an integrated PCBA assembly. The rigid PCB provides structural support and mounting for communication components (WiFi, Bluetooth, GPS), while the flexible circuit board establishes electrical connections with battery cells through busbars. This merging eliminates the need for separate interconnect and communication systems, achieving precise monitoring without proportionally increasing device complexity.
Solution Approach 2:
The PCBA assembly serves multiple functions simultaneously: it acts as a structural support for the battery module, provides electrical connections between cells and controller, hosts communication interfaces (WiFi, Bluetooth, GPS), and enables real-time data transmission. This multi-functionality allows the system to achieve comprehensive monitoring and control capabilities while using a single integrated component rather than multiple separate systems.
2Reliability
If integrated PCBA with flex circuit and busbars is used, then monitoring and control capabilities are enhanced, but manufacturing complexity increases
Solution Approach 1:
The flexible circuit board is pre-formed with busbars attached at specific locations before integration into the PCBA assembly. The busbars are pre-configured with connection points that align with battery cell terminals, and the flex circuit is pre-routed to connect these busbars to the rigid PCB. This preliminary preparation of connection elements simplifies the final assembly process, as components can be directly installed without complex on-site wiring or connection work.
3Stability of the object's composition
If rigid PCB and flexible circuit are integrally formed, then structural stability is improved, but packaging size increases
Solution Approach 1:
The patent uses a flexible circuit board instead of a completely rigid structure for the connection portion. The flex circuit provides necessary electrical connections while conforming to the available space within the battery module. This flexibility allows the assembly to be packaged in a compact form without requiring the additional clearance that would be needed for a fully rigid PCB structure, thus reducing overall packaging size while maintaining structural integrity.
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
This configuration enhances the monitoring and control of battery systems, optimizing performance and extending the life of battery packs by enabling precise cell balancing and thermal management, while reducing manufacturing complexity and packaging size.
Implementation Method 1
The PCB and the flex circuit are integrally formed as a unitary component. One approach for ensuring the requisite integration of the PCB and flex circuit is the use of a reflow surface-mounted technology (SMT) soldering process.
Implementation Method 2
The reflow process may be selective in nature, e.g., through local application of heat, as in an example 'hot bar' soldering. Alternatively, the reflow process may be global in nature, such as through the use of an SMT oven.
Implementation Method 3
The ICB assembly includes conductive bus bars, e.g., alternating copper and aluminum busbars in a possible embodiment, or busbars constructed of the same material, e.g., aluminum, copper, bimetal, or a combination thereof. A respective surface of each busbar is conductively joined to the flex circuit, while the busbar also conductively contacts and/or is conductively joined to a corresponding electrode terminal of a given battery cell.
Data Source
AI summary
An interconnect board (ICB) assembly is used with a battery module and a battery controller. The ICB assembly includes a printed circuit board assembly (PCBA) integrally formed from a printed circuit board (PCB) and a flex circuit. The PCB has a component surface populated with electronic components which measure and report parameters of the battery module to the battery controller. The flex circuit is constructed of conductive foil, and defines tabular flying leads that project from a periphery of the flex circuit. A window may be present in the flex circuit. A carrier frame has a support surface flanked by busbars. The PCBA is seated on the support surface, with the flying leads conductively joined to a corresponding busbar. A battery system includes the battery controller and the ICB assembly.