Battery Module Temperature Sensor Assembly Using Reinforced FPC
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Solution Overview
Problem
Existing battery modules face challenges in optimizing the assembly of temperature sensors due to interference with peripheral components and structural complexity, which affects the performance and ease of integration.
Innovation Solution
A battery module design incorporating a flexible printed circuit board unit with a reinforcing sheet, held by a busbar frame, allows for a simpler and more optimized coupling of a temperature sensor, using a frame structure that minimizes interference and enhances assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is assembled adjacent to the battery cell stack, then temperature measurement functionality is achieved, but interference with peripheral components occurs and assembly complexity increases
Solution Approach 1:
The temperature sensor is integrated with the flexible printed circuit board (FPC) assembly structure. The FPC serves dual purposes: as an electrical connection component and as a mounting substrate for the temperature sensor, eliminating the need for separate sensor mounting structures and reducing overall assembly complexity.
Solution Approach 2:
The flexible printed circuit board performs multiple functions simultaneously: providing electrical connections between battery cells, serving as a structural support element, and acting as a mounting platform for the temperature sensor. This multi-functionality reduces the number of separate components needed in the assembly.
2Measurement precision
If a temperature sensor is assembled adjacent to the battery cell stack, then temperature measurement functionality is achieved, but interference with peripheral components occurs
Solution Approach 1:
The flexible printed circuit board allows the temperature sensor to be mounted on a flexible substrate that can conform to available spaces and route around peripheral components. This dimensional flexibility enables the sensor to be positioned for optimal temperature measurement while avoiding interference with surrounding components through clever spatial arrangement.
3Reliability
If a complex assembly structure is used for the temperature sensor, then measurement functionality is ensured, but manufacturing and assembly difficulty increases
Solution Approach 1:
The temperature sensor is pre-mounted onto the flexible printed circuit board during FPC manufacturing or preparation, before the FPC is installed in the final assembly. This preliminary action ensures proper sensor positioning and connection while simplifying the final assembly process, as the sensor-FPC assembly can be installed as a single unit.
Data Source
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AI summary
A battery module according to one embodiment of the present disclosure includes a battery cell stack in which a plurality of battery cells are stacked; a busbar frame mounted onto the front and rear surfaces of the battery cell stack; and a flexible printed circuit board unit to which a temperature sensor for measuring the temperature of the battery cell stack is attached, wherein a reinforcing sheet is attached to the flexible printed circuit board unit.