Battery Module Circuit Board Bus Bar Integration
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Solution Overview
Problem
The existing storage battery module designs face challenges in assembling and transporting due to the stepped difference between bus bars and circuit boards, leading to poor assembly performance and increased time and labor, as the temperature sensor's lead terminal needs to be folded to connect, complicating the subassembly process.
Innovation Solution
The storage battery module incorporates a circuit board with lands for thermally bonding temperature sensors, which are connected via thermally conductive resin, and includes through holes for bus bar insertion, allowing for improved assembly efficiency by reducing the need for folding and enhancing thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature sensor is fastened to a bus bar and lead terminals are soldered to a circuit board, then temperature detection function is achieved, but assembly performance deteriorates due to stepped difference requiring lead terminal folding
Solution Approach 1:
The patent combines the bus bar and circuit board into a single integrated structure where the circuit board serves as the mounting base for both the temperature sensor and the bus bar connection. This integration eliminates the stepped difference between separate components, allowing lead terminals to be soldered directly without folding, thus improving assembly performance while maintaining temperature detection functionality.
Solution Approach 2:
The patent transitions from a three-dimensional stepped arrangement (bus bar at one level, circuit board at another) to a two-dimensional planar arrangement where all connections occur on the same plane. This dimensional change eliminates the need for lead terminal folding and simplifies the assembly process.
2Ease of manufacture
If the lead terminal is folded to connect bus bar and circuit board, then connection is achieved, but time and labor increase for storage and transportation in subassembled state
Solution Approach 1:
The patent performs the connection action preliminarily by integrating the bus bar and circuit board into a single assembly before storage and transportation. This preliminary integration eliminates the need for subsequent folding operations and reduces the time required for final assembly, as all connections are already in place in the subassembled state.
3Temperature
If temperature sensor is bonded to land with thermally conductive resin, then thermal conductivity is improved, but assembly complexity increases
Solution Approach 1:
The patent merges the temperature sensor mounting function with the circuit board structure by providing a dedicated land on the circuit board for sensor attachment. This integration consolidates multiple functions (electrical connection, mechanical support, thermal conduction) into a single component, reducing overall assembly complexity despite the addition of thermal conductive resin.
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
This design enhances assembly performance by simplifying the integration of temperature sensors, improving thermal conductivity, and reducing the complexity of the assembly process, thereby increasing productivity and efficiency.
Implementation Method 1
a temperature sensor that is thermally bonded to the land of the wiring and detects a temperature of the battery cell
Data Source
AI summary
A storage battery module 20 includes plural battery cells 320 in which a wound electrode group 322 having positive and negative electrodes, and positive and negative electrode collector plates 327a and 327b connected to the positive and negative electrodes are accommodated in a battery cell 321, and positive and negative external terminals 331 and 341 are provided to be exposed to outside of the battery case 321, a circuit board 350 including a temperature detecting wiring 302 of the battery cell 320 connected to the positive and negative external terminals 331 and 341, and a temperature sensor 381 for detecting a temperature of the battery cell 320 provided above the wiring 302.