Battery Wiring Module Layout With Perpendicular Busbars
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Solution Overview
Problem
The existing battery wiring module configurations for high-voltage battery packs, such as those in electric cars, are complex and require significant space due to the need to bend electrode leads to connect with busbars, making it difficult to secure a shape for positioning the busbar and reducing available space for other wiring components.
Innovation Solution
A battery wiring module configuration featuring busbars with a plate shape, a flexible printed circuit board, and a protector that holds these components perpendicularly, allowing direct connection of busbars to electrode leads without bending, thereby simplifying the structure and reducing the overall space required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar is arranged parallel to the side surface of the battery cell stack to connect with electrode leads, then the electrical connection is achieved, but the structure becomes complex and the space for positioning the busbar cannot be sufficiently secured
Solution Approach 1:
The busbar is arranged perpendicular to the side surface of the battery cell stack, changing the spatial dimension from parallel arrangement to perpendicular arrangement. This dimensional change allows the busbar to connect with electrode leads from a different orientation, simplifying the structure while maintaining electrical connection reliability and providing sufficient positioning space
2Reliability
If the busbar is arranged parallel to the side surface of the battery cell stack, then the electrical connection is achieved, but the space for the busbar assembly increases
Solution Approach 1:
By changing the busbar arrangement from parallel to perpendicular relative to the battery cell stack side surface, the spatial footprint is optimized. The perpendicular arrangement allows more efficient use of available space, reducing the overall volume required for the busbar assembly while maintaining proper electrical connections
3Reliability
If electrode leads are bent toward the busbar to achieve connection, then the electrical connection is established, but the configuration becomes complex
Solution Approach 1:
Instead of bending the electrode leads toward the busbar, the busbar is positioned perpendicular to the battery cell stack to directly align with and connect to the electrode leads. This inverted approach eliminates the need for bending operations, simplifying the overall configuration while ensuring reliable electrical connection
Data Source
AI summary
A battery wiring module is attached to a battery cell stack including a plurality of battery cells stacked and including electrode leads, to electrically connect the plurality of battery cells with each other. The battery wiring module includes: busbars having a plate shape; a flexible printed circuit board including board-side connection portions; and a protector holding the busbars and the flexible printed circuit board. The busbars include main bodies connected to the electrode leads, and busbar-side connection portions connected to the board-side connection portions. In the protector, the main bodies of the busbars, and the flexible printed circuit board are arranged perpendicularly to each other.