Universal Flex Circuit for Battery Module Configuration Adaptability
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Solution Overview
Problem
Existing battery module monitoring systems face challenges in accurately monitoring different battery configurations due to increased direct current internal resistance (DCIR) when the number of parallel groups of battery cells changes, leading to measurement errors if the flex circuit's conductive traces are not centered on each group.
Innovation Solution
A universal flex circuit with a greater number of connection terminals than electrical connections, allowing for flexible configuration to connect battery cells in various configurations, and an adaptable voltage-measuring device to ensure accurate voltage measurements across different battery configurations by selectively connecting subsets of terminals to a voltage-measuring device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flex circuit is designed with a fixed number of connection terminals for a specific battery configuration, then the manufacturing and installation are simplified, but the adaptability to different battery configurations is reduced
Solution Approach 1:
The flex circuit is designed with a universal set of connection terminals that can accommodate multiple battery configurations. The circuit board includes more connection terminals than the minimum required for any single configuration, allowing the same flex circuit to be used across different battery module designs without requiring custom configurations.
Solution Approach 2:
The system enables dynamic adaptation to different battery configurations by selectively connecting subsets of the available connection terminals. The monitoring circuitry can dynamically determine which terminals to use based on the detected battery configuration, allowing the same physical hardware to serve multiple purposes.
2Adaptability or versatility
If the number of connection terminals on the flex circuit is increased to accommodate different battery configurations, then the adaptability improves, but the device complexity increases
Solution Approach 1:
The flex circuit includes more connection terminals than the minimum required for any single battery configuration. This excessive provision of terminals allows the system to handle multiple configurations without requiring complex switching mechanisms, as the extra terminals simply remain unused for any given configuration rather than requiring active management.
Solution Approach 2:
The connection terminals are organized in a segmented pattern along the flex circuit, with groups of terminals positioned to correspond to different battery configurations. This segmentation allows the monitoring circuitry to selectively activate appropriate terminal groups based on the detected configuration, reducing the effective complexity for each specific use case.
3Device complexity
If the conductive traces are not centered on each parallel group of battery cells, then the flex circuit can be simplified, but measurement errors due to increased DCIR are introduced
Solution Approach 1:
The flex circuit acts as an intermediary between the battery cells and the monitoring circuitry, providing multiple connection terminals that can be selectively used to minimize measurement errors. By offering multiple terminal options for each battery group, the system can choose the terminal that provides the most accurate measurement while keeping the physical layout simple.
Solution Approach 2:
The system can change operational parameters by selecting different connection terminals based on the detected battery configuration. This allows the system to optimize measurement accuracy for each configuration by choosing terminals that minimize DCIR effects, rather than requiring fixed physical positioning of all terminals.
Data Source
AI summary
A battery module and a method of manufacturing a battery module are provided. The battery module includes a plurality of current collectors configured to electrically connect battery cells of the battery module together, and a flex circuit. The battery module is configured to have a number of electrical connections between the plurality of current collectors and the flex circuit. The flex circuit comprises a number of connection terminals, each capable of being electrically coupled to a current collector of the plurality of current collectors. The number of connection terminals is greater than the number of electrical connections. The electrical connections are made between the plurality of current collectors and a subset of the connection terminals of the flex circuit.