Multilayer PCB Cover Plate for High-Voltage Battery Connectors
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Solution Overview
Problem
High-voltage batteries face challenges with high production, assembly, and logistical costs due to complex manufacturing and assembly requirements, as well as susceptibility to corrosion and vibrations in existing connector designs.
Innovation Solution
A multilayer printed circuit board is used as the cover plate with thick and thin conductive layers for high-current connectors and cell monitoring connections, respectively, connected via conductive holes, eliminating the need for additional assembly and reducing component complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate conductors and plug-in connectors are used for cell monitoring connections, then electrical connectivity is achieved, but the connections are exposed to corrosion and vibrations causing malfunctions
Solution Approach 1:
The patent combines the cover plate, cell monitoring unit, and electrical connections into a single integrated printed circuit board assembly. The cover plate serves as the substrate, conductive layers provide electrical connections, and mounting structures secure battery cells, eliminating the need for separate plug-in connectors and individual conductors that are susceptible to corrosion and vibration damage.
2Ease of manufacture
If individual conductors are inserted and fastened into the cover plate, then electrical connections are established, but manufacturing and assembly complexity increases significantly
Solution Approach 1:
Multiple functions previously requiring separate components are merged into a single printed circuit board: the cover plate provides structural support, conductive layers establish electrical connections, and integrated mounting structures secure cells. This eliminates the need for inserting and fastening individual conductors, dramatically reducing assembly complexity.
Solution Approach 2:
The patent replaces mechanical connection methods (inserting and fastening individual conductors) with a printed circuit board technology that provides inherent electrical connections through conductive layers. The mechanical assembly is simplified to placing the integrated PCB assembly onto the battery structure, eliminating complex manual wiring operations.
3Adaptability or versatility
If differently arranged cell connectors and different cover plates are used for different vehicle designs, then customization requirements are met, but production and logistical costs increase
Solution Approach 1:
The integrated printed circuit board assembly serves multiple functions: structural cover plate, electrical connections for all cells, cell monitoring unit, and mounting structure. This multi-functional design allows the same basic assembly to be adapted to different vehicle configurations through software or minor modifications, reducing the need for completely different hardware designs for each application.
Data Source
AI summary
A high-voltage battery comprising a number of cells (2) that are arranged in rows, a support structure (3), and a cover plate on which high-current connectors (24) for the individual cells and a cell monitoring unit (9) are mounted. In order to reduce production, assembly, and logistics costs, the cover plate (6) is embodied as a multilayer printed board encompassing at least two conducting layers (15, 17). The first conducting layer (15) is mounted on the side of the printed board facing the cells (2) and has a considerable thickness in order to form the high-current connectors (24), while the second conducting layer (17) has a small thickness and forms the connecting lines (20) to the cell monitoring unit (9). The two layers (15, 17) are interconnected at certain points by means of conducting bores (19) that penetrate the printed board.