Rigid PCB Battery Pack Bus Bar Design
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Solution Overview
Problem
Existing battery packs face challenges in efficiently managing and connecting multiple battery cells for high-power applications, such as electric vehicles, due to limitations in output voltage and current, which require complex and unreliable connections.
Innovation Solution
A battery pack design incorporating a rigid printed circuit board (PCB) that electrically connects multiple battery cells and includes a battery management system (BMS) to control charge/discharge operations, with a bus and BMS integrated on a common base layer for improved rigidity and connectivity, and conductive regions on both surfaces for efficient electrode connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery cells are connected to increase output voltage and current for high-power applications, then the power output capability is improved, but the connection complexity and reliability deteriorate
Solution Approach 1:
The patent combines multiple battery cells into a single battery pack module with integrated PCB connectivity. The rigid PCB merges the electrical connection functions for multiple cells into one unified structure, reducing the number of separate connection components and simplifying the overall assembly while maintaining high power output capability through parallel cell connections.
Solution Approach 2:
The rigid PCB serves multiple functions simultaneously: it provides electrical connection between battery cells through bus bars, offers structural support for the battery pack, enables thermal management pathways, and integrates control electronics. This multi-functionality reduces the need for separate dedicated components for each function, thereby reducing overall connection complexity.
2Power
If multiple battery cells are connected to increase output voltage and current, then the power output capability is improved, but the connection reliability deteriorates
Solution Approach 1:
The rigid PCB integrates multiple connection points and bus bars into a single solid structure, reducing the number of separate connection interfaces that could fail. By merging individual cell connections into a unified rigid substrate, the system reduces potential failure points while maintaining the electrical connectivity needed for high power output.
Solution Approach 2:
The patent employs curved or bent bus bar configurations on the rigid PCB that provide mechanical compliance and stress distribution. These curved connection paths can accommodate thermal expansion and contraction without creating rigid stress concentrations that would lead to connection failure, thereby improving reliability while maintaining electrical connectivity.
3Reliability
If a rigid PCB is used to connect multiple battery cells, then the electrical connection stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The rigid PCB is designed as a modular assembly that can be manufactured separately and then integrated with the battery cells. The PCB itself can be segmented into different functional zones (connection areas, control areas, thermal management areas) that are manufactured using standardized PCB fabrication processes, reducing overall manufacturing complexity while maintaining connection stability.
Solution Approach 2:
The rigid PCB acts as an intermediary component that standardizes the connection interface between battery cells and the control system. By establishing a standardized PCB interface design, the manufacturing process benefits from repeatability and automation, reducing complexity despite the increased structural requirements for stable electrical connections.
Data Source
AI summary
A battery pack including a plurality of battery cells; and a rigid printed circuit board (PCB) electrically connected to each battery cell and extending across the plurality of battery cells, wherein the rigid PCB includes a bus to electrically connect the plurality of battery cells to each other, and a battery management system (BMS) to control a charge/discharge operation of the plurality of battery cells.