Flexible Battery Busbar Circuit for Vibration-Tolerant Connections
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Solution Overview
Problem
Existing battery connection modules have poor deformability and anti-vibration effects due to design tolerances and assembly deviations, leading to unstable electrical connections in battery devices, particularly in vehicle applications.
Innovation Solution
A battery connection module comprising a carrying tray, busbars, and a flexible circuit board with cantilevered connecting board bodies that extend in multiple directions, allowing for improved deformability and stable electrical connections, enhancing anti-vibration capabilities by forming gaps and using curved segments for better alignment with busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid connecting member is used to ensure structural stability, then manufacturing precision can be maintained, but deformability decreases leading to poor connection effects due to tolerances and assembly deviations
Solution Approach 1:
The connecting member is divided into a rigid main board body and flexible connecting boards with cantilevered portions. The main board body maintains structural stability and manufacturing precision, while the cantilevered portions provide deformability to accommodate tolerances and assembly deviations, resolving the contradiction between rigidity and adaptability.
Solution Approach 2:
The connecting boards are designed with cantilevered portions that can dynamically deform within gaps to adapt to position deviations between mating connecting pieces. This dynamic capability allows the structure to maintain reliable electrical connections despite variations in assembly precision.
2Manufacturing precision
If the connecting member is made rigid to maintain positional accuracy, then manufacturing precision is improved, but anti-vibration ability deteriorates
Solution Approach 1:
The gaps between the connecting boards and main board body, along with the curved segments in the cantilevered portions, are designed in advance to provide cushioning against vibration impacts. These features allow the connecting member to absorb vibrational energy before it can affect the electrical connections, maintaining position accuracy while improving anti-vibration ability.
3Device complexity
If simple straight connecting boards are used to reduce complexity, then device complexity is reduced, but deformability decreases leading to unstable connections
Solution Approach 1:
The cantilevered portions incorporate curved segments instead of straight lines, enabling the connecting boards to deform more effectively to accommodate position deviations. This curved geometry provides the necessary deformability for stable connections while adding minimal complexity to the overall structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves more stable electrical connections and improved anti-vibration effects by increasing the deformability of the connecting board bodies, effectively overcoming tolerance issues and ensuring reliable performance in battery devices.
Implementation Method 1
each connecting board body has a central portion and two cantilevered portions respectively extending at two opposite sides of the central portion in the longitudinal direction, each cantilevered portion has a proximal segment connected to the central portion, a distal segment opposite to the proximal segment and a curved segment positioned between the proximal segment and the distal segment
Data Source
AI summary
The present disclosure relates to a battery connection module and a battery device. The battery connection module includes a carrying tray, a plurality of busbars and a flexible circuit board. The plurality of busbars are provided to the carrying tray. The flexible circuit board is provided to the carrying tray and includes a main board body and a plurality of connecting board bodies integrally connected to the main board body in a floatable manner and respectively electrically connected to the plurality of busbars, each connecting board body is provided to a side edge of the main board body, extends in a longitudinal direction and faces the corresponding busbar in a transverse direction, each connecting board body has a central portion and two cantilevered portions respectively extending from two opposite sides of the central portion in the longitudinal direction, each cantilevered portion has a proximal segment connected to the central portion, a distal segment opposite to the proximal segment and a curved segment positioned between the proximal segment and the distal segment, the curved segment extends along at least the longitudinal direction and the transverse direction, each connecting board body is connected to the main board body only by the distal segments of the two cantilevered portions, a gap is formed between the connecting board body and the main board body.