Battery Module Bus Bar With Integrated Voltage Sensing Circuit
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Solution Overview
Problem
Existing battery modules face challenges with increasing numbers of battery cells, as traditional wire harnesses become bulky and flexible printed circuit assemblies (FPCAs) have high manufacturing costs due to complex processes.
Innovation Solution
A battery module with a coupling structure of a circuit for voltage measurement and a holder bus bar, where the voltage measurement circuit is integrally formed with the holder bus bar, reducing manufacturing costs and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wire harness is used to measure voltage of battery cells, then the structure is simple to manufacture, but the volume becomes excessively large when the number of battery cells increases
Solution Approach 1:
The patent combines the voltage measurement circuit with the holder bus bar into a single integrated component. The circuit board is positioned within the holder bus bar structure, merging two previously separate components (measurement circuit and structural support) into one unified assembly, thereby reducing overall volume while maintaining manufacturing simplicity
Solution Approach 2:
The holder bus bar is designed to serve multiple functions: it provides structural support for the battery cells, conducts electrical current, and houses the voltage measurement circuit. This multi-functional design eliminates the need for separate components, reducing volume while keeping the manufacturing process straightforward
2Volume of moving object
If an FPCA is used to measure voltage of battery cells, then the volume is reduced compared to wire harness, but the manufacturing cost increases due to complicated manufacturing process
Solution Approach 1:
The voltage measurement circuit is integrated directly into the holder bus bar structure, combining multiple functions into a single component that can be manufactured using conventional processes, thereby reducing volume without incurring the high costs associated with complex FPCA manufacturing
Solution Approach 2:
The patent employs a cost-effective circuit board design that can be manufactured using standard PCB processes rather than expensive flexible printed circuit assembly techniques, maintaining affordability while achieving compact dimensions
3Measurement precision
If wire harness or FPCA is used for voltage measurement, then the measurement function is achieved, but the assembly process becomes complex and productivity decreases
Solution Approach 1:
By integrating the voltage measurement circuit into the holder bus bar, the patent reduces the number of separate components that need to be assembled. The circuit board is positioned within the holder bus bar structure, allowing for simplified assembly operations and improved productivity while maintaining voltage measurement functionality
Solution Approach 2:
The holder bus bar is designed as a modular structure with a receiving space that accommodates the circuit board, allowing for easy assembly and disassembly. This segmented design enables rapid assembly operations while preserving the voltage measurement capability
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 solution reduces manufacturing costs and simplifies the assembly process, improving productivity by integrating the voltage measurement circuit with the holder bus bar, and allows for various connection forms between the voltage measurement circuit and the bus bar.
Implementation Method 1
a voltage measurement circuit portion (50) configured to measure a voltage of each of the plurality of battery cells
Implementation Method 2
an insulating film (60) covering the voltage measurement circuit portion
Data Source
AI summary
A battery module includes a bus bar configured to electrically connect a plurality of battery cells to each other, a holder bus bar configured to fix the bus bar, and a voltage measurement circuit portion configured to measure a voltage of each of the plurality of battery cells, and the voltage measurement circuit portion is integrally formed with the holder bus bar.