Bus Bar Module With Sliding Holders For Battery Pack Pitch Shifts
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Solution Overview
Problem
Conventional bus bar modules in battery packs face durability issues due to pitch shifts between electrode terminals, which can lead to assembly challenges and reduced durability from bending processes required to accommodate these shifts.
Innovation Solution
A bus bar module design featuring a flat cable with holding holes that allow relative movement of bus bars along the arranging direction, where a reference bus bar is fixed to maintain assembly alignment, and other bus bars can move to accommodate pitch variations, eliminating the need for bending parts and reducing load on the conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a U-shaped bending part is provided in the flat cable to accommodate pitch shifts between electrode terminals, then all bus bars can be inserted into the electrode terminals, but the durability of the flat cable is deteriorated by the load applied during bending and when the bending part expands or contracts
Solution Approach 1:
The bus bar module is divided into a reference bus bar and movable bus bars. The reference bus bar is fixed to the flat cable, while the movable bus bars can slide relative to the flat cable in the arranging direction. This segmentation allows pitch shifts to be accommodated by the movement of individual bus bars rather than requiring bending of the entire flat cable, thereby maintaining flat cable durability.
Solution Approach 2:
The holding holes in the flat cable are designed to allow relative movement of the movable bus bars in the arranging direction. This dynamic capability enables the bus bar module to adapt to pitch shifts between electrode terminals without requiring permanent deformation or bending of the flat cable, thus preserving its structural integrity and durability.
2Adaptability or versatility
If the pitch between adjacent electrode terminals shifts from the design value due to size variation and assembly variation, then assembly precision is compromised, but providing a bending part increases device complexity
Solution Approach 1:
The bus bar module is segmented into a fixed reference bus bar and movable bus bars that can independently adjust their positions. This segmentation allows the system to tolerate pitch variations without requiring a complex overall structure, as each movable bus bar can compensate for local pitch deviations.
Solution Approach 2:
The holding holes are designed with sufficient length in the arranging direction to allow the movable bus bars to slide and adjust their positions dynamically. This dynamic adjustment capability provides tolerance for pitch variations while maintaining a relatively simple and straightforward structural design.
Data Source
AI summary
A bus bar module includes a plurality of bus bars each having a through hole into which an electrode terminal of an electrode terminal group arranged in a line on a battery module formed of a plurality of battery cells is inserted, the bus bars being arranged along an arranging direction of the electrode terminal in the electrode terminal group, and a flat cable including a conductor part electrically connected to the bus bars, and an insulating holding part for holding the bus bars. The bus bar includes a holding body to be fitted to the flat cable. The holding part has a holding hole for each of the bus bars that allows a relative movement of the bus bar with respect to the flat cable in the arranging direction, by allowing a relative movement of the inserted holding body in the arranging direction.