Busbar Module With Flexible Circuits for Battery Stack Variation
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Solution Overview
Problem
Existing busbar modules face challenges in ease of assembly and adaptability to deformation and manufacturing variations in battery assemblies, particularly when the number of stacked battery cells increases.
Innovation Solution
A busbar module design featuring a first and second circuit body formed from flexible substrates with specific wiring patterns, busbars connected to cell electrodes, electronic components attached to branch line portions, and an extensible and contractible holder to accommodate these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of electric wires is increased to monitor more battery cells, then the monitoring capability is improved, but the rigidity of the voltage detection line increases making assembly more difficult
Solution Approach 1:
The voltage detection line is divided into multiple independent flexible circuits instead of using a single bundled wire structure. Each flexible circuit can independently connect to battery cells, allowing the system to maintain monitoring capability while improving flexibility and ease of assembly.
Solution Approach 2:
The patent uses flexible circuits with thin film structures instead of rigid bundled wires. These flexible circuits can bend and adapt to the expansion and contraction of battery cells during charging and discharging, maintaining electrical connection while improving ease of assembly and adaptability.
2Reliability
If the number of electric wires is increased to monitor more battery cells, then the monitoring capability is improved, but the ability to expand and contract sufficiently is reduced
Solution Approach 1:
The voltage detection line is designed with dynamic flexibility using flexible circuits that can expand and contract. This allows the structure to adapt to the thermal expansion and contraction of battery cells during operation, maintaining reliable electrical connections throughout the battery pack's lifecycle.
Solution Approach 2:
Flexible circuit boards with thin film structures are used instead of rigid wire bundles. These flexible circuits can bend and deform with the battery cells, maintaining electrical connection reliability while accommodating thermal deformation and manufacturing variations.
3Adaptability or versatility
If a certain margin in length is designed to cope with deformation and manufacturing variation, then adaptability is improved, but the rigidity increases making assembly more difficult
Solution Approach 1:
The patent employs flexible circuits with inherent flexibility to accommodate manufacturing variations and deformations. The flexible nature of these circuits allows them to adapt to length variations and positional deviations without requiring excessive margin length, thereby maintaining ease of assembly while improving adaptability.
Solution Approach 2:
The flexible circuits are designed with variable physical parameters such as length, width, and bending radius that can be adjusted during manufacturing. This allows the voltage detection line to adapt to different battery cell configurations and manufacturing tolerances while maintaining ease of assembly through optimized geometric parameters.
Data Source
AI summary
A busbar module includes a first circuit body, a second circuit body, and an electronic component. First and second wiring patterns are electrically connected to each other at an overlapping portion of first and second main line portions. Among a plurality of first and second contact portions, a first and second wiring portion extends from one of the first and second contact portions to one side in an intersecting direction intersecting a stacking direction, and a first and second wiring portion extends from the other first and second contact portion to the other side in the intersecting direction.