Modular FPCB Assembly Layout to Reduce Battery Module Scrap
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Solution Overview
Problem
Conventional flexible printed circuit boards (FPCBs) for battery modules waste significant material due to their geometric shapes, leading to excessive scrap and increased costs, as they are often cut or stamped into specific shapes like I-type, E-type, or F-type, resulting in unused space.
Innovation Solution
A FPCB assembly design featuring a main FPCB portion and sub FPCB portions with connector terminals that can be assembled in various configurations, such as I, T, or E shapes, minimizing unused space by using connector pins to connect unit FPCBs in a straight shape, allowing for efficient space utilization and reduced scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If FPCB is cut or stamped into specific shapes (I-type, E-type, F-type) from a FPCB sheet, then the FPCB can be designed to fit complex product configurations, but excessive unused space remains leading to increased material cost
Solution Approach 1:
The FPCB is divided into multiple separate strips that are connected through holes, rather than cutting a single complex-shaped board from a sheet. This segmentation allows the strips to be arranged flexibly to form different configurations (I-type, E-type, F-type) while minimizing waste from the original sheet.
Solution Approach 2:
Multiple FPCB strips are nested together by inserting them through common holes, creating a compact assembled structure. This nesting approach allows efficient space utilization on the FPCB sheet during manufacturing while maintaining the ability to form complex configurations when assembled.
2Adaptability or versatility
If FPCB is designed in complex shapes (E-type, F-type) to accommodate additional sensors, then functional requirements are met, but material cost increases due to excessive scraps
Solution Approach 1:
The FPCB is segmented into multiple strips that can be independently arranged to accommodate sensors at different positions. This segmentation allows functional requirements to be met through configuration rather than complex shaping, minimizing material waste.
Solution Approach 2:
Instead of adding complexity in the two-dimensional plane (complex shapes), the solution moves to a three-dimensional arrangement where multiple strips are stacked and connected through holes. This dimensional transition allows sensor integration without increasing material waste.
3Reliability
If conventional harness wire is used for voltage sensing and signal transmission, then electrical connection is achieved, but space inside the battery module is wasted and connector contact problems occur
Solution Approach 1:
The patent uses a thin FPCB structure instead of bulky harness wires. The FPCB's flexible film construction provides reliable electrical connections while occupying minimal space within the battery module, solving both the reliability and space utilization problems.
Data Source
AI summary
A flexible printed circuit board (FPCB) assembly for a battery module includes a insulated flexible film and conductor patterns arranged inside the film in a predetermined form, and the conductor patterns transmit an electric signal. The FPCB assembly includes a main FPCB configured to extend in one direction; and a sub FPCB assembled to at least one side of the main FPCB and configured to extend in a direction different from the main FPCB.