VARIABLE LENGTH BUSBAR MODULE FOR AN ELECTRIC VEHICLE

Abstract

A variable-length busbar module for a vehicle comprises: a first busbar assembly coupled to a first substrate, a second busbar assembly coupled to a second substrate, and an intermediate busbar assembly for connecting the first and second busbar assemblies, the intermediate busbar assembly being configured to be supplied in various lengths. The variable-length busbar module enables product standardization by requiring only the length of the intermediate busbar assembly when different busbar lengths are needed due to a housing design. The first and second busbar assemblies are interchangeable.

Description

BACKGROUND(a) Technical field

[0001] The present disclosure relates to a variable-length busbar module used for electrical connection between printed circuit boards (PCBs), in particular a variable-length busbar module used for electrical connection between printed circuit boards (PCBs) that is capable of achieving product standardization by only changing the length of a busbar intermediate assembly when busbars of different lengths are required due to a housing design. (b) Description of the technology referred to

[0002] A busbar is a metal strip or rod used for the efficient transmission of electrical energy. Typically made primarily of copper, a busbar serves to transmit or distribute electrical current within an electrical system, and can thus replace certain existing cables.

[0003] Busbars are essential components of electrical switches, distribution boards, voltage converters, battery components, etc. Due to the rapid expansion of electric vehicles in recent years, busbars are also used as essential components in a power conversion device that includes an integrated charge control unit (ICCU), an on-board charger (OBC), a DC-DC converter, and the like, installed in an electric vehicle.

[0004] Busbars are typically used to create connections between multiple points that require an electrical connection while minimizing power loss, and are designed to improve the stability of an electrical system.

[0005] Fig. Figure 1 (RELATED TECHNOLOGY) is a perspective view depicting a power conversion device installed on an electric vehicle and showing the arrangement of a plurality of PCB substrates within the power conversion device. In particular, this perspective view shows that a busbar 10 is mounted as a means of electrical connection between a first substrate 20 and a second substrate 30, which are arranged at different heights.

[0006] As in Fig. As shown in Figure 1, the busbar can form 10 different busbars of different lengths depending on the arrangement of the first substrate 20 and the second substrate 30, and new busbars of different lengths can be manufactured each time the specifications of an electric vehicle, such as a power conversion device of the electric vehicle being developed, are changed, causing problems that require mold costs for the manufacture of new busbars, performance analysis and certification of the newly manufactured busbars, production plans, etc.

[0007] For example, Korean patent no. 10-1652495 discloses a busbar whose length is adjustable. The busbar has a structure comprising at least one connecting wire for joining a first busbar and a second busbar, wherein the first busbar and the second busbar are composed of a body having a wire receiving part and a fixing part that presses and secures the connecting wire, and are provided with a structure for adjusting the length of the connecting wire to be inserted.

[0008] The busbar of the patent described above has the advantage of having a variable-length structure, but has the limitation of being structurally weak for use in automobiles, which are subject to vibrations and impacts / shocks of various frequency bands and intensities, due to the structure of the fixing part, which is configured to connect a side surface of a wire with a screw.

[0009] Therefore, it would be desirable to develop a busbar capable of transmitting stable power while overcoming the problems of conventional busbars. EXPLANATION

[0010] One objective of the present disclosure is to provide a variable-length busbar module, e.g. for use in an electric vehicle, which is capable of achieving product standardization by only changing the length of a busbar intermediate assembly when busbars of different lengths are required due to a housing design.

[0011] According to the present disclosure, a variable-length busbar module for a vehicle comprises: a first busbar assembly coupled to a first substrate; a second busbar assembly coupled to a second substrate; and a busbar intermediate assembly for connecting the first busbar assembly and the second busbar assembly to each other, the busbar intermediate assembly being configured to be provided in different lengths.

[0012] Furthermore, the first busbar assembly and the second busbar assembly are configured to be used interchangeably.

[0013] According to one aspect of the present disclosure for solving the problems, a variable-length busbar module is provided comprising: a first busbar assembly coupled to a first substrate; a second busbar assembly coupled to a second substrate; and a busbar intermediate assembly for connecting the first busbar assembly and the second busbar assembly to each other, wherein the first busbar assembly and the second busbar assembly can be used interchangeably (e.g., jointly), and the busbar intermediate assembly can be provided in different lengths to accommodate different enclosure specifications.

[0014] Here, the first busbar assembly can be composed of an injection-molded body into which a first busbar is inserted.

[0015] Furthermore, the first busbar can be L-shaped, and an L-shaped horizontal part can be arranged on / at a bottom surface side of the first substrate.

[0016] Furthermore, the first busbar may have a perforation hole formed in the L-shaped horizontal part to be coupled to the first substrate by inserting a screw into one side of the perforation hole and attaching a nut to the other side of it.

[0017] In this case, the first busbar can have the nut that is press-fitted into a lower inner side of the perforation hole.

[0018] Furthermore, N first busbars can be inserted horizontally side by side into the body of the first busbar assembly and

[0019] N-1 shielding walls can be designed vertically to subdivide perforation holes of the N inserted first busbars.

[0020] Here, an insulating plate for electrical insulation can be inserted into the inside of each shielding wall.

[0021] According to another aspect of the present disclosure for solving the problems, the second busbar assembly of the present disclosure can be composed of an injection-molded body into which a second busbar is inserted.

[0022] Furthermore, load-supporting projections can be formed at a predetermined height in a longitudinal direction in a front surface of the body of the second busbar assembly, and a fastening projection inserted into a coupling hole of the second substrate can be designed to extend downwards from each projection.

[0023] Furthermore, N second busbars can be inserted horizontally side by side into the body of the second busbar assembly,

[0024] N load-support projections can be formed side by side at a predetermined height in a longitudinal direction on a front surface of the body where the N inserted second busbars are arranged, and N fastening projections inserted into coupling holes of the second substrate can be formed to extend downwards from the projections.

[0025] Furthermore, separate from the N fastening projections, an anti-misassembly projection can be designed to prevent misassembly by extending from the body of the second busbar assembly.

[0026] Meanwhile, through holes (352) can be formed in the body of the second busbar assembly such that a lower surface of a recessed part (312b) of the second busbar (310) is arranged in a central part of each through hole.

[0027] According to another aspect of the present disclosure for solving the problems, the busbar intermediate assembly of the present disclosure can be composed of an injection-molded body into which an intermediate busbar is inserted.

[0028] Furthermore, the first busbar, the second busbar and the intermediate busbar can be composed of protruding parts and recessed parts to form connecting surfaces through surface contacts.

[0029] Furthermore, each injection-molded body can be made from a thermally conductive polymer as a single material.

[0030] According to an exemplary embodiment of the present disclosure, if busbars of different lengths are required due to the housing design, a first busbar assembly and a second busbar assembly coupled to a substrate side are provided for common use, and only one intermediate busbar assembly having different lengths is replaced, making it able to accommodate product layouts with different specifications.

[0031] In particular, the exemplary embodiments of the present disclosure provide specifications for a busbar intermediate assembly of different lengths, so that a user can immediately apply busbars without the need to manufacture the busbars of the specifications desired by the user and to undergo testing and certification prior to introduction.

[0032] The coupling structure of a busbar intermediate assembly coupled to a first busbar assembly and a second busbar assembly can always be manufactured and managed uniformly, thus preventing a problem of conventional length-adjustable busbar products where the electrical properties of the busbar change when the contact area changes with each length change.

[0033] An electric vehicle can include the busbar module.

[0034] According to the present disclosure, a method for forming a variable-length busbar module for a vehicle may comprise: coupling a first busbar assembly to a first substrate; coupling a second busbar assembly to a second substrate; and connecting the first busbar assembly and the second busbar assembly via a busbar intermediate assembly, wherein the busbar intermediate assembly is configured to be provided in different lengths. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 (RELATED TECHNOLOGY) is a perspective view representing a power conversion device equipped with a conventional busbar and shows a partially enlarged view of the busbar. Fig. 2A and Fig. 2B are installation views showing a busbar module with different lengths according to an exemplary embodiment of the present disclosure. Fig. Figure 3 is an assembly view showing a variable-length busbar module according to an exemplary embodiment of the present disclosure. Fig. Figure 4 is an exploded view showing the variable-length busbar module according to an exemplary embodiment of the present disclosure. Fig. 5A and Fig. Figure 5B represents a perspective view and a cross-sectional view, respectively, which represent a first busbar assembly of the variable-length busbar module according to an exemplary embodiment of the present disclosure. Fig. 6A and Fig. Figure 6B shows, in an associated manner, a perspective view and a front view of a second busbar assembly of the variable-length busbar module according to an exemplary embodiment of the present disclosure. Fig. Figure 7 is a front view of a second busbar assembly of a variable-length busbar module according to a further exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0035] It is understood that the term "vehicle" or "vehicle..." or any other similar term as used herein generally includes motor vehicles, such as passenger cars, including SUVs, buses, trucks, various commercial vehicles, watercraft, including a variety of boats and ships, aircraft, and the like, and hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles, and other alternative fuel vehicles (e.g., fuels derived from resources other than petroleum). As defined herein, a hybrid vehicle is a vehicle that has two or more power sources, for example, both gasoline-powered and electric-powered vehicles.

[0036] The terminology used herein serves only to describe certain embodiments and is not intended to limit the present disclosure. As used herein, the singular forms "a" and "the" are intended to include the plural forms unless the context clearly indicates otherwise. Furthermore, it is understood that the terms "has" and / or "having" when used in this description specify the presence of specified features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed elements.Throughout the description, unless explicitly stated otherwise, the word "include" and variations such as "shows" or "showing" are understood to imply the inclusion of specified elements, but not the exclusion of any other elements. Additionally, the terms "-unit," "-er," "-or," and "module" as described here refer to units for processing at least one function and operation and may be implemented by hardware components or software components and combinations thereof.

[0037] Furthermore, the control logic of the present disclosure can be embodied as non-volatile, computer-readable media on a computer-readable medium containing executable program instructions that are executed by means of a processor, a control device, or the like. Examples of computer-readable media include, but are not limited to, ROM, RAM, compact disc (CD)-ROMs, magnetic tapes, floppy disks, flash drives, smart cards, and optical data storage devices. The computer-readable medium can also be distributed in network-connected computer systems, such that the computer-readable medium is stored and executed in a distributed manner, e.g., by means of a telematics server or a controller area network (CAN).

[0038] Preferred exemplary embodiments of the present disclosure are described in detail below with reference to the drawings.

[0039] Fig. 2A and Fig. 2B are installation views that depict a busbar module 100 of different lengths according to an exemplary embodiment of the present disclosure and that show a state in which the busbar module 100 of the present disclosure electrically connects a first substrate 20 and a second substrate 30, which are arranged at a distance from each other in the vertical direction.

[0040] Fig. Figure 2A shows an installation example of the busbar module 100 when the distance between the first substrate 20 and the second substrate 30 is short, and Fig. Figure 2B shows an installation example of the busbar module 100 when the distance between the first substrate is 20 and the second substrate is 30.

[0041] Next is Fig. 3 an assembly view showing a variable-length busbar module according to an exemplary embodiment of the present disclosure, and Fig. Figure 4 is an exploded view showing the variable-length busbar module according to an exemplary embodiment of the present disclosure.

[0042] With reference to Fig. 3 and Fig. 4 comprises the variable-length busbar module 100 according to an exemplary embodiment of the present disclosure: a first busbar assembly 200 coupled to a first substrate 20; a second busbar assembly 300 coupled to a second substrate 30; a busbar intermediate assembly 400 configured to connect the first busbar assembly 200 and the second busbar assembly 300, wherein the first busbar assembly 200 and the second busbar assembly 300 are used interchangeably regardless of enclosure specifications, and the busbar intermediate assembly 400 is provided in different lengths to accommodate different enclosure specifications.

[0043] Here, the first busbar assembly 200, the second busbar assembly 300 and the intermediate busbar assembly 400 can be composed of injection-molded bodies into which the first busbar 210, the second busbar 310 and the intermediate busbar 410 are inserted in an associated manner.

[0044] For easier understanding, in the case of Fig. 3 and Fig. 4 The body of the busbar intermediate assembly 400 is shown transparently and only expressed with outlines, and in the case of Fig. Figure 4 shows the body of the first busbar assembly 200 as translucent. Similar to the second busbar assembly 300, the intermediate busbar assembly 400 and the first busbar assembly 200 can, however, be composed of respective injection-molded bodies into which an intermediate busbar 410 and a first busbar 210 are inserted in an associated manner.

[0045] Additionally, the injection-molded bodies 250, 350 and 450 of the first busbar assembly 200, the second busbar assembly 300 and the intermediate busbar assembly 400 can be made of engineering plastic as one material.

[0046] In addition, these injection-molded bodies can preferably be made from a thermally conductive polymer as a material, and such a thermally conductive polymer can be produced by adding carbon-based particles or fibers, which have excellent electrical / thermal conductivity properties, as an additive to existing plastic materials, such as polypropylene (PP) and polystyrene (PS).

[0047] If the bodies of the first busbar assembly 200, the second busbar assembly 300 and the intermediate busbar assembly 400 are made of a material with good thermal conductivity, it is possible to improve the heat dissipation effect of these busbar assemblies for transmitting high power.

[0048] Additionally, as in Fig. Figure 4 shows that projecting parts 213a, which are formed on both sides of the lower end of the L-shaped vertical part 213 of the first busbar 210, are fixedly attached to recessed parts 412b, which are formed on both sides of the upper part of the intermediate busbar 410, and a recessed part 213b, which is formed in the lower end center of the vertical part 213, is fixedly attached to a projecting part 412a, which is formed in the center of the upper part of the intermediate busbar 410.

[0049] Additionally, the projecting parts 213a, which are formed on both sides of the lower end of the L-shaped vertical part 213 of the first busbar 210, can be configured to be exposed by a body 250 of the first busbar assembly 200, and recessed parts 412b, which are formed on both sides of the upper part of the intermediate busbar 410, can be configured as grooves, each having a predetermined depth from the upper surface of the intermediate busbar assembly 400, by means of a wall formed by the projecting part 412a, which is formed in the middle of the upper part of the intermediate busbar 410, and a body 450 of the intermediate busbar 410, which is injection molded to surround the recessed parts 412b.

[0050] Additionally, the recessed part 312b, which is formed in the middle of the upper part of the second busbar 310, is firmly attached to the projecting part 413a, which is formed in the middle of the lower part of the intermediate busbar 410, and the projecting parts 312a, which are formed on both sides of the upper part of the second busbar 310, are firmly attached to the recessed parts 413b, which are formed on both sides of the lower part of the intermediate busbar 410.

[0051] In addition, the projecting parts 312a, which are formed on both sides of the upper part of the second busbar 310, are designed to be exposed by a body 350 of the second busbar assembly 300, and the recessed parts 413b, which are formed on both sides of the lower part of the intermediate busbar 410, can be formed as respective grooves, each having a predetermined depth from the lower surface of the intermediate busbar assembly 400, by means of a wall formed by the projecting part 412a, which is formed in the middle of the upper part of the intermediate busbar 410, and the body 450 of the intermediate busbar 410, which is injection molded to surround the corresponding areas.

[0052] The above description is based on the one in Fig. 4 configuration shown, but as a further exemplary embodiment of the present disclosure, if required, a protruding part can be formed in the middle of the upper part of the second busbar 310, and a recessed part can be formed in the middle of the lower part of the intermediate busbar 410, so that the second busbar assembly and the intermediate busbar assembly can also be coupled together.

[0053] In the exemplary embodiments described above, the recessed part 213b, which is formed in the middle of the L-shaped vertical part 213 of the first busbar 210, can also be placed in the protruding part, which is formed in the middle of the upper part of the second busbar 310, in order to respond to the shortest distance between the first substrate 20 and the second substrate 30.

[0054] Next are Fig. 5A and Fig. 5B in an associated manner a perspective view and a cross-sectional view which represent a first busbar assembly of the variable-length busbar module according to an exemplary embodiment of the present disclosure. Fig. 6A and Fig. Figure 6B are, in an associated manner, a perspective view and a front view, which represent a second busbar assembly of the variable-length busbar module according to an exemplary embodiment of the present disclosure. Fig. Figure 7 is a front view of a second busbar assembly of a variable-length busbar module according to a further exemplary embodiment of the present disclosure.

[0055] The following describes the configuration of the first busbar assembly 200 and the second busbar assembly 400 with reference to Fig. Sections 5A to 7 are described in more detail.

[0056] With reference to Fig. 5A and Fig. 5B, according to the exemplary embodiments of the present disclosure, the first busbar assembly 200, as described above, can be composed of the injection-molded body 250 into which the first busbar 210 is inserted. In this case, the first busbar 210 has an L-shape, and a horizontal part 212 of an L-shape can be arranged on a lower surface side of the first substrate 20.

[0057] Furthermore, the first busbar 210 has a perforation hole 211 formed in the L-shaped horizontal part 212 to be connected to the first substrate 20 by inserting a screw 230 into one side of the perforation hole 211 and fastening a nut 220 into the other side of it.

[0058] Furthermore, in the first busbar 210, the nut 220 can be press-fitted into the lower inner side of the perforation hole 211, or internal screw threads can be formed on / in the inner circumferential surface of the perforation hole 211.

[0059] According to such a configuration, while the first substrate 20 is arranged on the side of the horizontal part 212 of the first busbar 210, which is inserted into the first busbar assembly 200 of the present disclosure, as shown in Fig. As shown in Figure 5B, the first busbar assembly 200 is / will be firmly coupled to the first substrate 20 by combining the screw 230 and the nut 220 or the screw 230 and the internal screw thread formed on / at the inner circumferential surface of the perforation hole 211.

[0060] Furthermore, as shown in the drawings of Fig. As shown in Figures 3 to 5B, two first busbars are inserted horizontally side by side into the body of the first busbar assembly 200, and a shielding wall can be formed vertically to divide the perforation holes of the two inserted first busbars. In particular, an upper shielding wall 252 and a lower shielding wall 253 can be formed vertically within the shielding wall. An insulating plate for electrical insulation can be inserted into each of the upper shielding wall 252 and the lower shielding wall 253.

[0061] As in Fig. As shown in Figure 3, the upper shielding wall 252 is inserted into and coupled to a cut-out part 22 of the first substrate 20, not only to ensure a secure connection between the body 250 of the first busbar assembly 200 and the first substrate 20, but also to shield a space between the heads of the screw-connected screws 230, which are inserted into the coupling holes 21 of the first substrate 20, thus preventing an unexpected short circuit, etc.

[0062] Furthermore, as in Fig. 3 and Fig. As shown in Figure 5B, the body 250 of the first busbar assembly 200 is formed in the L-shape, the upper shielding wall 252 is formed such that it extends upwards from the upper surface of the horizontal part 251 of the L-shape, the lower shielding wall 253 is formed such that it extends downwards from a lower surface of the horizontal part 251, so that the shape formed by means of the horizontal part 251, the upper shielding wall 252 and the lower shielding wall 253 is preferably a +-shape when viewed from the front (i.e. in the direction of a positive (+) x-axis direction), which serves to increase the structural stiffness / strength of the first busbar assembly 200 coupled to the first substrate.

[0063] Next, with reference to Fig. 6A and Fig. 6B, as described above, the second busbar assembly 300 is composed of an injection-molded body into which the second busbar 310 is inserted. Load-supporting projections 353 can be formed at / at a predetermined height in the longitudinal direction on / at a front surface of the body of the second busbar assembly 300. A fastening projection 354, inserted into each coupling hole of the second substrate 30, can be configured to extend downwards from each projection 353.

[0064] In Fig. 6A and Fig. 6B shows each projection 353 that is formed in the direction of a front direction (i.e. in the direction of a negative (-) x-axis direction) of the body 350 of the second busbar assembly 300, but it is understood that each projection can be formed in the direction of a rear direction (i.e. in the direction of the positive (+) x-axis direction) as required, or each projection can be formed in both the front direction (the negative (-) x-axis direction) and the rear direction (the positive (+) x-axis direction) of the body.

[0065] Furthermore, the I-shaped second busbar 310 can be inserted into the I-shaped vertical part 351 of the body 350 of the second busbar assembly 300. The projecting parts 312a and 313a and the recessed parts 312b and 313b can be formed on the upper part 312 and the lower part 313 of the second busbar 310 so that they are exposed by the upper and lower surfaces of the vertical part 351 of the body 350. In this case, the projecting part 313a of the lower part of the second busbar 310 can be inserted into a mounting hole provided in the second substrate 30 and connected by soldering to a printed circuit provided in the second substrate.

[0066] Furthermore, as shown in the drawings of Fig. 4, Fig. 6A, Fig. 6B and Fig. Figure 7 shows two second busbars 310 inserted horizontally side by side into the body of the second busbar assembly 300, two load-supporting projections are formed side by side at / in a predetermined height in the longitudinal direction on / in the front surface of the body where the two inserted second busbars are arranged, and two fastening projections inserted into the coupling holes of the second substrate can be designed to extend downwards from the respective projections.

[0067] Furthermore, as in Fig. 6A and Fig. Figure 6B shows that the body 350 of the second busbar assembly 300 has a misassembly prevention projection 355 designed to prevent misassembly in such a way that it extends separately from the body and the two fastening projections 354.

[0068] Furthermore, as yet another exemplary embodiment of the present disclosure, as in Fig. Figure 7 shows that through-holes 352 are formed in a body 350 of a second busbar assembly 300 of the present disclosure, such that the central part of a through-hole 352 is arranged on a lower surface of a recessed part 312b of a second busbar 310. In this case, it is preferred that a projecting part 413a of an intermediate busbar 410 of a busbar intermediate assembly 400, wherein the projecting part 413a is set into the recessed part 312b of the second busbar 310, is formed such that it projects outwards from the lower surface of the intermediate busbar 410, so that the distal end surface of the projecting part 413a of the lower part of the intermediate busbar 410 is in contact with a lower surface of the recessed part 312b of the upper part of the second busbar 310.

[0069] Furthermore, while the distal end surface of the protruding part 413a of the lower part of the intermediate busbar 410 and the lower surface of the recessed part 312b of the upper part of the second busbar 310 are in contact with each other, a soldering tool can be inserted into the through holes 352 to perform soldering, thereby maximally reducing the contact resistance between busbars.

[0070] Furthermore, it goes without saying that the through holes 352 can also be formed in the busbar intermediate assembly 400 or the first busbar assembly 200 as required.

[0071] As described above, show Fig. 4, Fig. 5, Fig. 6 to Fig. 7 only that the two first busbars 210 and the two second busbars 310 are inserted horizontally side by side in an assigned manner into the bodies of the first busbar assembly 200 and the second busbar assembly 200. If required, however, N (N is an integer greater than or equal to 2) first busbars 210 and two second busbars 310 can be inserted horizontally side by side in an assigned manner into the bodies of the first busbar assembly 200 and the second busbar assembly 200.

[0072] Furthermore, in this case, N-1 shielding plates configured to subdivide the perforation holes of the N inserted first busbars can be formed vertically in the body 250 of the first busbar assembly 200. N load-supporting projections 353 can be formed side by side at a predetermined height in the longitudinal direction on the front surface of the body where the N inserted second busbars are arranged in the body of the second busbar assembly 350. Mounting projections 354, to be inserted into coupling holes of the second substrate, can be configured to extend downwards from these projections.

[0073] Next, with reference to Fig.4, as described above, the intermediate busbar assembly 400 may be composed of the injection-molded body into which the intermediate busbar is inserted, and as described above, the first busbar 210, the second busbar 310 and the intermediate busbar 410 may be composed of the foregoing parts 213a, 312a, 412a and 413a and the recessed parts 213b, 312b, 412b and 413b to form connecting surfaces by surface contacts with each other.

[0074] As described above, only specific exemplary embodiments were described in the detailed description of the present disclosure. However, the present disclosure should not be interpreted as being limited to the specific modes referred to in the detailed description, but rather as covering modifications, equivalents, or alternatives within the idea and scope of the embodiment of the present disclosure as disclosed in the appended claims. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] KR 10-1652495

[0007]

Claims

[1] Variable-length busbar module for a vehicle, which has: a first busbar assembly coupled to a first substrate; a second busbar assembly coupled to a second substrate; and a busbar intermediate assembly for connecting the first busbar assembly and the second busbar assembly to each other, the busbar intermediate assembly is configured to be provided in different lengths. [2] Busbar module according to claim 1, wherein the first busbar assembly and the second busbar assembly are configured to be used interchangeably. [3] Busbar module according to claim 1, wherein the first busbar assembly is composed of an injection-molded body and a first busbar is configured to be inserted into the first busbar assembly. [4] Busbar module according to claim 3, wherein the injection-molded body is made of a thermally conductive polymer. [5] Busbar module according to claim 3, wherein the first busbar is L-shaped and an L-shaped horizontal part is arranged on a lower surface side of the first substrate. [6] Busbar module according to claim 5, wherein the first busbar has a perforation hole formed in the L-shaped horizontal part to be coupled to the first substrate by inserting a screw into one side of the perforation hole and attaching a nut to the other side thereof. [7] Busbar module according to claim 6, wherein the first busbar has the nut which is press-fitted into a lower inner side of the perforation hole. [8] Busbar module according to claim 6, wherein N first busbars are inserted horizontally side by side into the body of the first busbar assembly and N-1 shielding walls are designed vertically to subdivide perforation holes of the first busbars used in the N. [9] Busbar module according to claim 8, wherein an insulating plate for electrical insulation is inserted into an inner side of each shielding wall. [10] Busbar module according to claim 1, wherein the second busbar assembly is composed of an injection-molded body and a second busbar is configured to be inserted into the second busbar assembly. [11] Busbar module according to claim 10, wherein the injection-molded body is made of a thermally conductive polymer. [12] Busbar module according to claim 10, wherein projections for load support are formed at a predetermined height in a longitudinal direction in a front surface of the body of the second busbar assembly and a fastening projection, which is inserted into a coupling hole of the second substrate, is formed such that it extends downwards from each projection. [13] Busbar module according to claim 10, wherein N second busbars are inserted horizontally side by side into the body of the second busbar assembly, N load-supporting projections are formed side by side at a predetermined height in a longitudinal direction on a front surface of the body, where the N inserted second busbars are arranged, and N fastening projections, which are inserted into coupling holes of the second substrate, are designed such that they extend downwards from the projections. [14] Busbar module according to claim 13, wherein, separate from the N fastening projections, an anti-misassembly projection is designed to prevent misassembly such that it extends from the body of the second busbar assembly. [15] Busbar module according to claim 10, wherein through holes are formed in the body of the second busbar assembly such that a lower surface of a recessed part of the second busbar is arranged in a central part of each through hole. [16] Busbar module according to claim 1, wherein the intermediate busbar assembly is composed of an injection-molded body and an intermediate busbar is configured to be inserted into the intermediate busbar assembly. [17] Busbar module according to claim 16, wherein the injection-molded body is made of a thermally conductive polymer. [18] Busbar module according to claim 1, which further comprises a first busbar, a second busbar and an intermediate busbar, wherein one or more of the first busbar, the second busbar or the intermediate busbar are composed of protruding parts or recessed parts to form connecting surfaces by surface contacts with each other. [19] Electric vehicle comprising the busbar module according to claim 1. [20] Method for forming a variable-length busbar module for a vehicle, wherein the method comprises: Coupling a first busbar assembly with a first substrate; Coupling a second busbar assembly with a second substrate; and Connecting the first busbar assembly and the second busbar assembly via an intermediate busbar assembly, the busbar intermediate assembly is configured to be provided in different lengths.

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