Battery Wiring Module Busbar Segmentation and Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery wiring modules for in-vehicle battery packs face challenges in durability due to non-uniform voltage across battery cells, increased resistance leading to voltage drops, and high manufacturing costs, with limited versatility due to dedicated insulation frames and complex wiring structures.
Innovation Solution
A method involving the coating of elongated flat plate conductors and linear conductors with insulating resin, forming busbars by separating the conductors, and connecting them to electrode terminals with a simplified structure that includes terminal insertion holes and cut raised portions for improved connection and reduced weight, allowing for flexible adaptation to different battery cell sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar module with multiple voltage detection lines is used to monitor battery cell voltage, then battery cell voltage monitoring capability is improved, but the bound voltage detection lines become thickened and heavier, making wiring more difficult
Solution Approach 1:
The patent divides the single thick busbar module into multiple separate thin busbars, each with its own voltage detection line. This segmentation allows each detection line to remain thin and flexible while collectively providing comprehensive voltage monitoring across multiple battery cells, resolving the contradiction between monitoring capability and wiring flexibility.
Solution Approach 2:
The patent transitions from a planar arrangement where multiple detection lines are bound together in one dimension to a three-dimensional arrangement where multiple thin busbars are distributed spatially. This dimensional change allows each detection line to be routed independently through available space, maintaining thinness and flexibility while achieving comprehensive monitoring coverage.
2Reliability
If round terminals are crimped to voltage detection lines and fixed with nuts to busbars, then electrical connection is established, but contact surface resistance increases causing voltage drop
Solution Approach 1:
The patent extracts and eliminates the round terminal and nut components from the connection system. By directly connecting the flat conductor of the busbar to the battery cell terminal through a simplified clamp structure, the patent removes the intermediate contact surfaces that caused high resistance and voltage drop, while maintaining reliable electrical connection.
Solution Approach 2:
Instead of the conventional approach of connecting detection lines to busbars through terminals and nuts, the patent inverts the connection methodology by having the busbar directly contact the battery cell terminal. This inversion eliminates the multi-step connection process and reduces contact resistance, resolving the voltage drop issue.
3Reliability
If dedicated insulation frames with specific protrusion and opening configurations are used, then battery cell connection is achieved, but versatility decreases and manufacturing cost increases
Solution Approach 1:
The patent replaces the dedicated insulation frame with a universal busbar design that can be configured for different battery cell sizes and arrangements. The busbars maintain electrical connection functionality while the insulation function is provided by separate insulating materials, allowing the same busbar structure to serve multiple battery pack configurations and applications.
Solution Approach 2:
The patent segments the integrated insulation frame structure into separate functional components: the busbars for electrical connection and independent insulating materials for electrical isolation. This segmentation allows the busbars to be designed purely for their electrical connection function, improving versatility while maintaining connection reliability through proper insulation application.
Data Source
AI summary
Provided is a method for manufacturing battery wiring module including: a coating step of coating one long side portion of an elongated flat plate conductor and outer peripheral portions of linear conductors disposed in parallel along the long side portion with a predetermined gap therebetween having a predetermined gap with respect to the long side portion by a first insulating resin portion; and a pressing step of separating the flat plate conductor at a predetermined gap in the longitudinal direction of the flat plate conductor and forming a plurality of busbar electrically connecting electrode terminals provided in at least two battery cells connected to each other in the same direction among the plurality of battery cells overlapping each other in the same direction, the electrode terminals being arranged in parallel in the same direction.