Oblique PCB Connection Member for Flexible Battery Pack Assembly
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Solution Overview
Problem
Existing battery pack connecting elements and printed circuit boards face challenges in achieving high connection reliability while being easy to produce, particularly in terms of mechanical and electrical stability, and require methods that are cost-effective and flexible for various battery cell configurations.
Innovation Solution
A connecting element with a bottom section for battery cell connection and an obliquely projecting edge section for circuit board connection, made of conductive and weldable/solderable material, allows for secure mechanical and electrical connections. The element is designed to be flexible, enabling various battery pack configurations with reduced part diversity, and is manufactured through processes like stamping and embossing, with optional coatings for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a connecting element is designed with separate bottom section and edge section for flexible configuration, then adaptability is improved, but device complexity increases
Solution Approach 1:
The connecting element is designed as a universal component that can serve multiple functions: the bottom section connects to battery cells while the edge section connects to the printed circuit board. This single component replaces what would otherwise require multiple different parts, achieving flexible battery pack configurations without increasing overall device complexity.
Solution Approach 2:
The connecting element is divided into functional sections (bottom section for battery cell connection and edge section for PCB connection), allowing each section to be optimized for its specific purpose while maintaining overall simplicity. The segmentation enables adaptable configurations without requiring complex multi-component assemblies.
2Reliability
If conventional connecting elements are used without oblique edge section, then manufacturing is simpler, but connection reliability deteriorates
Solution Approach 1:
The edge section is designed to project obliquely from the bottom section, introducing a dimensional aspect that improves connection reliability. This oblique projection enables better mechanical engagement with the printed circuit board while maintaining compatibility with standard manufacturing processes like stamping and embossing, thus not significantly increasing manufacturing complexity.
3Reliability
If material selection is restricted to basic conductive materials, then manufacturing cost is lower, but connection reliability deteriorates
Solution Approach 1:
The connecting element is made from electrically conductive materials that are also solderable and/or weldable, creating a composite material solution that simultaneously achieves reliable electrical connection, mechanical strength, and ease of manufacture. This multi-functional material selection ensures high connection reliability without requiring expensive specialized materials or complex manufacturing processes.
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
The solution provides a simple, cost-effective method for producing battery packs with high mechanical and electrical reliability, allowing for flexible battery cell configurations and reduced part diversity, while ensuring secure connections via welding or soldering.
Implementation Method 1
The connecting element is made of an electrically conductive, solderable and/or weldable material and/or has a weldable, solderable and/or electrically conductive coating
Implementation Method 2
The connecting element is made of an electrically conductive, solderable and/or weldable material and/or has a weldable, solderable and/or electrically conductive coating
Data Source
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AI summary
The invention relates to a connecting element for a printed circuit board for a battery pack, a printed circuit board for a battery pack, and a battery pack with at least one battery cell, wherein the connecting element (10) has a base section (12) for electrical and mechanical connection with the battery cell and an edge section (13) projecting obliquely from the base section (12) for electrical and mechanical connection with the printed circuit board, and wherein the connecting element (10) is made of an electrically conductive, solderable, and/or weldable material and/or has at least a portion of a weldable, solderable, and/or electrically conductive coating. The invention further relates to a method for manufacturing a printed circuit board and a method for manufacturing a battery pack. The invention also relates to the use of a printed circuit board for manufacturing a battery pack.