Bus Bar Module Flexible Flat Conductor Rigidity
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Solution Overview
Problem
Conventional bus bar modules face challenges in assembling workability due to variations in expansion and contraction of mountain fold-shaped parts, leading to differences in rigidity and position adjustments of bus bars relative to electrode terminals.
Innovation Solution
A bus bar module with flexible flat conductors and insulating holding members, featuring conductive portions with extension sections and electric connecting portions, and bus bar holders that include connection areas in a mountain fold shape to absorb tolerance variations and reduce rigidity differences, allowing for improved flexibility and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mountain fold shape is applied to conductive portions to absorb tolerance variations, then flexibility is improved, but rigidity is lowered and difference in expansion/contraction between adjacent bus bars occurs
Solution Approach 1:
The connection areas are segmented into individual mountain fold-shaped parts for each bus bar, allowing each segment to independently absorb tolerance variations. This segmentation enables localized flexibility while maintaining overall structural stability through the distributed arrangement of multiple connection areas along the bus bar assembly.
Solution Approach 2:
The mountain fold shape is applied locally only to the connection areas where flexibility is needed to absorb tolerance variations, while the main body of the bus bars and holding members maintains rigid structural properties. This localized application of flexibility resolves the contradiction by providing adaptability only where required without compromising overall rigidity.
2Adaptability or versatility
If mountain fold shape is applied to conductive portions, then tolerance variations are absorbed, but assembling workability is reduced due to position adjustment requirements
Solution Approach 1:
The mountain fold-shaped connection areas are designed to automatically absorb tolerance variations and self-adjust during the assembly process without requiring manual position adjustment of each bus bar. The flexible connection areas naturally accommodate misalignments between bus bars and electrode terminals, enabling the assembly to complete itself with minimal intervention and improving assembling workability.
3Reliability
If conductive portions are arranged in a row to connect electrode terminals, then electrical connection is achieved, but rigidity differences cause position adjustment issues
Solution Approach 1:
The connection areas are designed with dynamic flexibility through the mountain fold shape, allowing them to adapt their configuration during assembly to accommodate position variations. This dynamic characteristic enables the rigid bus bars to be connected to electrode terminals with consistent electrical connection while automatically compensating for position inconsistencies without requiring manual adjustment.
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 solution enhances assembling workability by reducing the difference in rigidity and expansion/contraction of connection areas, facilitating easier position adjustment of bus bars and improving durability by maintaining consistent intensity levels across connection areas.
Implementation Method 1
each of the connection areas is formed in a mountain fold shape so as to expand and contract in the arrangement direction
Data Source
AI summary
A bus bar module includes a plurality of bus bars, conductive portions for the respective bus bars, and a flexible flat conductor that includes insulating holding members each holding each of the conductive portions and each of the bus bars. The flexible flat conductor includes conductor connection areas for the respective bus bars in which the bus bar and an electric connecting portion are electrically connected to each other, and a connection area that connects the adjacent conductor connection areas in an arranging direction of the bus bars. Each of the conductor connection areas is formed in a mountain fold shape so as to expand and contract in the arranging direction, and is formed so as to reduce a difference in rigidity between the conductor connection areas.