Bus Bar Module Flat Circuit Board Insulation
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Solution Overview
Problem
Conventional bus bar modules require excessive synthetic resin for insulation, increasing manufacturing costs and component count due to separate housing and FFC cover components.
Innovation Solution
A bus bar module design featuring a flat circuit board that covers openings between bus bars, reducing the need for synthetic resin and separate coupling members, with housings having opposite walls and a continuing wall to secure the circuit board, which also couples adjacent housings without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate housing and FFC cover components are used for insulation, then insulation reliability is improved, but manufacturing cost and component count increase
Solution Approach 1:
The patent merges the housing and FFC cover into a single integrated housing component. The housing includes a body portion that houses the bus bar and a cover portion that covers the FFC, eliminating the need for separate FFC cover components. This integration reduces component count while maintaining insulation reliability through the continuous housing structure.
Solution Approach 2:
The housing serves multiple functions simultaneously: it houses the bus bar, covers the FFC for insulation, and provides structural support. The integrated design makes the housing a multi-functional component that replaces what were previously separate specialized components, reducing overall device complexity.
2Reliability
If excessive synthetic resin is used for insulation, then insulation performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the FFC from the housing interior and routes it through a designated opening in the housing. This allows the FFC to be insulated by the housing structure itself rather than requiring excessive synthetic resin fillers. The opening provides a controlled path for the FFC while maintaining insulation with minimal material usage.
Solution Approach 2:
The housing acts as a flexible insulating shell that covers the FFC through its cover portion. This thin-walled housing structure provides adequate insulation without requiring thick layers of synthetic resin, reducing material cost while maintaining insulation performance.
3Manufacturing precision
If separate FFC cover is provided to hold FFC, then FFC positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The FFC positioning and holding functions are merged into the housing structure itself. The housing includes a specific opening that guides and positions the FFC, eliminating the need for separate FFC cover components. This integration maintains positioning accuracy through the precisely formed opening while reducing component count.
Data Source
AI summary
Disclosed is a bus bar module and a power source unit capable of reducing manufacturing cost thereof. A bus bar module (1) includes a plurality of bus bars (3) arranged in line so as to connect a plurality of batteries (3) in series; a plurality of housings (50) housing each of the bus bars (3) and each including a placement part (51) on which each of the bus bar (3) is placed; a pair of opposite walls (52) upstanding from the placement, part (51) and opposed to each other, a continuing wall (52) continuous with the pair of opposite walls (52), and an opening (54) located opposed to the continuing wall (53); and a flat circuit board (4) connected to each of the bus bars (3) and arranged in an arrangement direction X of the bus bars (3), the flat circuit board (4) being, with a width direction thereof along an upstanding direction of the pair of opposite walls (52), attached to the housings (50) so as to cover the opening (54).