Battery Wiring Module Manufacturing via Insulated Busbar Segmentation
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Solution Overview
Problem
Existing battery wiring modules for in-vehicle battery packs face challenges in durability due to non-uniform voltage across battery cells, leading to potential voltage drop and increased manufacturing costs, with limited versatility and complex wiring processes.
Innovation Solution
A method involving coating elongated flat plate conductors with insulating resin, forming busbars by separating the conductors, and connecting them to electrode terminals, allowing for flexible configuration and reduced manufacturing costs while maintaining electrical connectivity.
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 the reliability of voltage detection is improved, but the weight and flexibility of the wiring deteriorate due to the bound state of multiple lines
Solution Approach 1:
The patent divides the single thick bound bundle of voltage detection lines into multiple separate thin lines. Each line is individually routed and connected to specific busbars, transforming one heavy bound structure into multiple lightweight separate elements that maintain detection reliability while improving flexibility and reducing weight.
Solution Approach 2:
The patent transitions from a one-dimensional bound bundle structure to a two-dimensional distributed arrangement where multiple voltage detection lines are separately routed across the battery module surface, connecting to different busbars at different positions, thereby improving flexibility and weight distribution.
2Ease of manufacture
If round terminals are crimped and fixed to busbars with nuts to enable voltage detection, then the ease of assembly is improved, but the electrical resistance at contact surfaces increases causing voltage drop
Solution Approach 1:
The patent removes the round terminal and nut components from the connection structure. Instead of crimping round terminals and securing them with nuts, the voltage detection lines are directly connected to the busbars through welding or other direct bonding methods, eliminating the intermediate components that cause contact resistance.
Solution Approach 2:
The patent merges the voltage detection line connection with the busbar structure itself, creating an integrated connection where the detection line is directly bonded to the busbar surface. This eliminates separate terminal components and reduces the number of contact interfaces, thereby reducing resistance and improving electrical reliability.
3Ease of manufacture
If insulation frames with protrusion portions are used to arrange busbars and flat cables, then the ease of assembly is improved, but the adaptability to different battery pack types deteriorates due to dedicated designs
Solution Approach 1:
The patent creates a universal busbar and voltage detection line arrangement system that can be adapted to different battery pack types. The method uses standardized connection procedures and flexible routing that can accommodate various battery cell configurations, replacing dedicated insulation frame designs with a more versatile approach.
Solution Approach 2:
The patent introduces flexibility and adjustability to the busbar arrangement system. Instead of fixed dedicated insulation frames, the system allows for dynamic adjustment of busbar positions and voltage detection line routing to accommodate different battery pack configurations, thereby improving adaptability while maintaining ease of assembly.
4Ease of manufacture
If multiple connection members are inserted and molded into insulating resin to form busbar modules, then the ease of assembly is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the insert-molding process from the manufacturing method. Instead of inserting connection members into insulating resin and molding them together, the busbars and voltage detection lines are manufactured separately and then assembled through simpler connection methods such as welding or mechanical fastening, thereby reducing manufacturing process complexity.
Solution Approach 2:
The patent divides the integrated busbar module into separate components: busbars, voltage detection lines, and insulating structures are manufactured independently and then assembled. This segmentation simplifies the manufacturing process for each component while maintaining the functional integration of the final assembly, reducing overall manufacturing complexity.
Data Source
AI summary
Provided is a method for manufacturing a battery wiring module including: a coating step of coating a first long side portion of a flat plate conductor and a plurality of linear conductors following the first long side portion by a first insulating resin portion and of coating a second long side portion of the flat plate conductor and a plurality of linear conductors following the second long side portion by a second insulating resin portion; and a cutting step of cutting the insulating resin portion so that the plurality of busbars is divided into a plurality of busbar groups and the plurality of linear conductors coated by any one of the first insulating resin portion and the second insulating resin portion and the busbar groups are separated.