Busbar Module Case Structure for Flexible Substrate Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing busbar modules with flexible substrates lack sufficient freedom in routing, limiting their adaptability and efficiency in connecting battery modules.
Innovation Solution
A busbar module design featuring a flexible substrate with a trunk portion and branch portions that can be routed at various positions, held by a case with specific holding structures, allowing for improved flexibility and adaptability in substrate routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible substrate is used in a busbar module, then adaptability in connecting battery modules is improved, but the degree of freedom in routing the flexible substrate is insufficient
Solution Approach 1:
The flexible substrate is divided into a main body and multiple branched portions, allowing independent routing of each branch to different battery module positions. This segmentation enables the substrate to adapt to various connection configurations while maintaining routing flexibility through the modular branch structure.
Solution Approach 2:
The patent introduces a vertical dimension by positioning holding portions at different heights within the case. The first holding portion is positioned at a different height than the second holding portion, allowing the flexible substrate to be routed in three-dimensional space rather than constrained to a single plane, thereby increasing routing freedom.
2Manufacturing precision
If the flexible substrate is routed with fixed holding positions, then manufacturing precision is improved, but adaptability to varying battery module configurations deteriorates
Solution Approach 1:
Multiple holding portions are provided at different positions and heights within the case, allowing selection of appropriate holding positions based on specific battery module configurations. This segmentation provides both precision through defined holding locations and adaptability through multiple options.
Solution Approach 2:
The case structure with multiple holding portions at different heights serves multiple functions: it provides precise positioning when needed while also enabling adaptation to various battery module arrangements. The same structure universally handles both fixed-precision applications and variable-configuration scenarios.
3Ease of operation
If the flexible substrate is made more flexible for routing freedom, then ease of operation is improved, but reliability of electrical connection deteriorates
Solution Approach 1:
The flexible substrate is pre-formed with branched portions and holding portions positioned at specific locations before assembly. This preliminary configuration allows the substrate to be easily routed during assembly while the pre-positioned holding portions ensure reliable electrical connections are maintained once assembled.
Solution Approach 2:
The patent uses a flexible substrate with controlled flexibility that can be routed freely during assembly but maintains sufficient rigidity when held in position to ensure reliable electrical connections. The flexible substrate acts as both a routing-friendly component and a connection-stable conductor.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A busbar module (5) includes a case (6) that is assembled to a battery module (2), and a flexible substrate (7) that is held in the case (6). A main body (71) of the flexible substrate (7) includes a trunk portion (711), and a branch portion (712) branched from the trunk portion (711). Meanwhile, the case (6) includes a trunk holding portion (61), a branch holding portion (62) that is positioned closer to the battery module (2) side than the trunk holding portion (61), and a connecting wall (63) that connects the trunk holding portion (61) and the branch holding portion (62). The trunk holding portion (61), the branch holding portion (62), and the connecting wall (63) form a stepped portion. Further, the branch portion (712) includes a curved portion (7122) that curves smoothly in a connecting portion with the trunk portion (711). A holding portion (64) that holds the main body (71) in a state in which a curved shape of the curved portion (7122) is maintained is formed in the case (6).