Busbar Module Case for Curved Flexible Substrate Routing
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Solution Overview
Problem
Existing busbar modules with flexible substrates lack sufficient freedom in routing, leading to inefficiencies and potential damage during assembly due to sharp corners and increased material waste.
Innovation Solution
A busbar module design featuring a case with a trunk holding portion, branch holding portion, and connecting wall forming a stepped portion, along with a smoothly curved branch portion, allows for improved flexibility in routing the flexible substrate by maintaining the curved shape and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible substrate is used in a busbar module, then electrical connection flexibility is improved, but routing freedom is insufficient due to sharp corners and rigid structural constraints
Solution Approach 1:
The patent applies curvature by replacing sharp corners with smooth curved surfaces in the case structure. The connecting walls between holding portions are formed with curved surfaces that allow the flexible substrate to be routed smoothly without sharp bends, thereby improving routing freedom while maintaining structural integrity.
Solution Approach 2:
The case is segmented into multiple holding portions (trunk holding portion, first branch holding portion, second branch holding portion) connected by connecting walls. This segmentation allows each portion to be optimized for specific routing needs while the overall structure provides coordinated support for the flexible substrate.
2Ease of manufacture
If sharp corners are used in the case structure, then manufacturing is simpler, but assembly damage occurs to the flexible substrate
Solution Approach 1:
Sharp corners in the case structure are replaced with smooth curved surfaces at the connecting walls between holding portions. This eliminates stress concentration points that would damage the flexible substrate during assembly, while the curved surfaces are still manufacturable using standard molding techniques.
3Volume of moving object
If the flexible substrate is routed with sharp bends, then space utilization is improved, but material waste increases and substrate integrity is compromised
Solution Approach 1:
The connecting walls are designed with curved surfaces that guide the flexible substrate through smooth transitions between holding portions. This allows efficient space utilization within the case while preventing sharp bends that would cause material waste and substrate damage.
Solution Approach 2:
The patent changes the geometric parameters of the case structure by introducing curved surfaces with specific radii of curvature. These parameter changes optimize the balance between space utilization and substrate protection, allowing the flexible substrate to be routed efficiently without sharp bends.
Data Source
AI summary
A busbar module includes a case that is assembled to a battery module, and a flexible substrate that is held in the case. A main body of the flexible substrate includes a trunk portion, and a branch portion branched from the trunk portion. Meanwhile, the case includes a trunk holding portion, a branch holding portion that is positioned closer to the battery module side than the trunk holding portion, and a connecting wall that connects the trunk holding portion and the branch holding portion. The trunk holding portion, the branch holding portion, and the connecting wall form a stepped portion. Further, the branch portion includes a curved portion that curves smoothly in a connecting portion with the trunk portion. A holding portion that holds the main body in a state in which a curved shape of the curved portion is maintained is formed in the case.