PCB Panel Power Module Assembly for Dense Multi-Unit Connections
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Solution Overview
Problem
Existing power modules face challenges in achieving high power density while maintaining flexibility and reducing assembly costs, particularly due to the high number of connections required between smaller power units.
Innovation Solution
The electric power module comprises a plurality of power units juxtaposed transversally, with first and second panels featuring terminal contact elements aligned with the electrodes of the power units, allowing for automated assembly and reduced wiring operations through the use of printed circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If smaller power units (cylindrical) are used to achieve high power levels, then flexibility and cost of basic units are improved, but the number of connections required increases significantly, leading to increased assembly costs and time
Solution Approach 1:
The patent merges multiple connection functions into a single integrated panel structure. The panel combines multiple contact elements for electrical connections with structural support functions, eliminating the need for separate wiring operations for each power unit. This reduces the number of discrete connection operations while maintaining the flexibility of using smaller cylindrical power units.
Solution Approach 2:
The panel serves multiple functions simultaneously: it provides structural support for the power units, establishes electrical connections through integrated contact elements, and enables automated assembly through its standardized interface design. This multi-functionality reduces the overall complexity of the assembly system.
2Reliability
If wire bonding method is used to make connections, then electrical connections between power units are established, but the assembly process cannot be automated, resulting in long assembly times for high power levels
Solution Approach 1:
The patent replaces the manual wire bonding mechanical process with an automated panel-based connection system. The contact elements on the panel establish electrical connections through standardized mechanical interfaces that can be engaged by automated assembly equipment, eliminating the need for manual wire bonding operations while maintaining connection reliability.
Solution Approach 2:
The connection elements are pre-configured on the panel before assembly. This preliminary arrangement of contact elements allows automated assembly systems to quickly establish connections without requiring complex real-time positioning operations, thereby reducing assembly time while ensuring reliable electrical contacts.
3Device complexity
If prismatic batteries are used as basic units, then the number of connections is reduced, but the cost of basic units increases and flexibility is reduced
Solution Approach 1:
The patent segments the connection system into modular contact elements on the panel, which can interface with standardized power units. This segmentation allows the use of smaller, more flexible cylindrical power units while the modular panel structure efficiently manages the connections, avoiding the need for expensive prismatic battery units.
Data Source
AI summary
An electric power module comprises: a plurality of electric power units, each of which extends along a longitudinal direction from a first end, including a first electrode, to a second end, including a second electrode; a first panel, including a first plurality of contact elements, each of which is in contact with the first electrode of a corresponding power unit; a second panel, including a second plurality of contact elements, each of which is in contact with the second electrode of a corresponding power unit. In the module, the first panel comprises a first plurality of holes, each of which is aligned, along the longitudinal direction, with a respective contact element of the first plurality of contact elements and with a respective first electrode, and the second panel comprises a second plurality of holes, each of which is aligned, along the longitudinal direction, with a respective contact element of the second plurality of contact elements and with a respective second electrode.