Modular Flex Circuit Sense-Line Integration for Variable Battery Series Counts
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Solution Overview
Problem
Existing battery technologies rely on mechanical connectors for connecting sense line assemblies, which can be cumbersome and may require additional manufacturing steps.
Innovation Solution
A method is introduced that utilizes a battery cell sensing application specific integrated circuit (ASIC) with channels and weld pads, along with shunts and flexible circuits, to connect sense lines without mechanical connectors, allowing for modular configurations and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical connectors are used to connect sense line assemblies, then reliable electrical connection is achieved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent extracts and eliminates the mechanical connector component from the sense line assembly. The sense lines are directly integrated onto the circuit board through PCB trace connections and surface mount technology, removing the need for separate mechanical connectors while maintaining reliable electrical connection.
Solution Approach 2:
The patent merges the sense line connection function directly into the PCB structure. The sense lines are integrated as PCB traces that connect battery terminals to the management IC, combining the connection function with the board structure itself rather than using separate connector components.
2Ease of operation
If mechanical connectors are used for sense line assemblies, then flexible connection is achieved, but manufacturing steps and time increase
Solution Approach 1:
The patent replaces the mechanical connector system with an electrical/PCB-based connection system. Sense lines are routed as PCB traces and connected through standard PCB mounting techniques, substituting mechanical assembly with automated PCB manufacturing processes that improve productivity.
Solution Approach 2:
The sense line connections are pre-integrated into the PCB structure during board manufacturing. The PCB is designed with built-in trace routes and connection points before final assembly, allowing sense lines to be connected as part of the board fabrication process rather than requiring separate assembly steps.
3Ease of manufacture
If modular components with fixed circuit configuration are used, then manufacturing simplicity is achieved, but adaptability to different series counts is limited
Solution Approach 1:
The patent implements a dynamic circuit configuration system where sense line connections can be selectively enabled or disabled through PCB design options. The board includes multiple sense line traces that can be activated or deactivated based on the specific battery configuration, allowing the same modular component to adapt to different series counts.
Solution Approach 2:
The PCB design incorporates universal connection capabilities that support multiple battery configurations. The same base module can be adapted to different series counts by selectively activating different sense line connections, making the modular component universally applicable across various battery designs.
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 approach simplifies the manufacturing process by eliminating mechanical connectors, enabling flexible and efficient integration of sense line assemblies in batteries.
Implementation Method 1
welding a first shunt to the first weld pad and the second weld pad
Data Source
AI summary
Disclosed is a method which may include providing a battery cell sensing application specific integrated circuit comprising at least a first channel and a second channel, a first connection line connected to the first channel and a second connection line connected to the second channel, a first weld pad connected to the first connection line, a second weld pad connected to the second connection line, and binding a first shunt to the first weld pad and the second weld pad.