Battery Connection Module With Notched Busbars for Compact Flex Routing
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Solution Overview
Problem
Existing battery connection modules face issues with deformation limitations in flexible printed circuit boards, leading to potential damage during transverse displacement and increased space occupation due to the need for separate busbar and wiring member spacing, as well as insulation damage from torque forces and external forces.
Innovation Solution
A battery connection module design featuring a carrying tray with busbars and flexible circuit boards, where the busbars have notches for bending arms to ensure compactness and flexibility, and an insulative base with a gap to prevent direct contact and enhance stability, along with a connector system integrated into the tray for secure and compact assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the busbar and the wiring member are spaced apart to provide space for the branch section to extend, then the branch section can be properly positioned, but additional space is occupied
Solution Approach 1:
The branch section is nested within the notch of the busbar, allowing the wiring member to be positioned correctly without requiring additional space between the busbar and wiring member. The notch provides the necessary space for the branch section to extend while maintaining compact overall dimensions.
Solution Approach 2:
The notch is formed on the side of the busbar toward the flexible circuit board, creating a three-dimensional space that accommodates the branch section. This side-oriented notch structure allows the branch section to extend in a direction that does not increase the overall footprint or space occupation of the assembly.
2Adaptability or versatility
If the flexible printed circuit board has a branch section that is deformable in response to displacement in the longitudinal direction, then the connection can accommodate longitudinal movement, but it cannot respond to displacement in the transverse direction which may damage the connection
Solution Approach 1:
The bending arm is designed as a dynamic component that can deform in response to both longitudinal and transverse displacements. The elastic material allows the bending arm to flex and adapt to movements in multiple directions, maintaining reliable electrical connection while accommodating various displacement scenarios.
Solution Approach 2:
The bending arm is made of elastic material with specific mechanical properties that allow it to change its shape and flexibility parameters. This enables the bending arm to respond to different displacement magnitudes and directions, providing both adaptability and connection reliability under varying operational conditions.
3Device complexity
If the insulation is supported only by the conductor and the conductor and insulation affect each other, then the structure is simplified, but the insulation is prone to generate rotation and damage under torque force
Solution Approach 1:
The insulative base is segmented into multiple independent support portions that are distributed around the conductor. This segmentation allows each support portion to independently bear torque forces, preventing rotation and damage to the insulation while maintaining a relatively simple overall structure.
Solution Approach 2:
The insulative base provides localized support at specific positions around the conductor, creating areas of enhanced mechanical strength where needed. This local reinforcement approach maintains simplicity in non-critical areas while providing adequate torque resistance at critical support points.
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 allows for improved compactness, reduced space occupation, enhanced durability against displacement and external forces, and secure connection of components, ensuring reliable electrical connections and structural integrity.
Implementation Method 1
the bending arm can respond to displacement of the busbar, thereby ensuring the connection relationship between the flexible circuit board and the busbar
Data Source
AI summary
A battery connection module includes a carrying tray, a plurality of busbars and a flexible circuit board. The plurality of busbars are provided on the carrying tray. The flexible circuit board is provided on the carrying tray, the plurality of busbars is adjacent to the flexible circuit board, and the busbar has a notch which is formed to a side toward the flexible circuit board and a notch side plate portion which is positioned alongside the notch, the flexible circuit board has a bending arm which integrally extend out from the flexible circuit board, the bending arm is positioned in the notch of the busbar and a tip of the bending arm is electrically connected to the busbar. In some embodiments, a battery connection module further includes an output connection port provided to the carrying tray. In some embodiments, a battery connection module further includes a connector provided to the carrying tray.