Battery Busbar Wiring Module With Flexible Fuse Coupling
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Solution Overview
Problem
Conventional busbar assemblies for high-voltage battery packs in electric vehicles lack a fuse function, and incorporating a circuit board with a fuse increases manufacturing costs and is prone to damage from temperature changes.
Innovation Solution
A wiring module that includes a busbar connected to power storage device electrode terminals, a flexible board with a conductive path and a fuse portion, a metal piece connecting the busbar to the flexible board, and an electric wire, where the flexible board has a coupling portion allowing displacement relative to the metal piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circuit board with a fuse is incorporated into the wiring module, then the fuse function is provided, but the manufacturing costs increase
Solution Approach 1:
The fuse function is extracted from a traditional circuit board and integrated directly into the flexible board structure. The flexible board itself is designed with a fuse portion that can break under excessive current, eliminating the need for a separate circuit board with fuse while maintaining the protective function and reducing manufacturing complexity
Solution Approach 2:
The fuse function is merged with the flexible board by incorporating a fuse portion directly into the board's conductive path. This integration combines the structural support function of the flexible board with the protective fuse function, eliminating the need for a separate circuit board component and reducing overall manufacturing costs
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 proposed wiring module reduces manufacturing costs by minimizing the use of flexible boards and enhances durability by allowing displacement of the metal piece relative to the board, thus maintaining electrical connections despite temperature changes or external forces.
Implementation Method 1
temperature changes that occur during vehicle use cause the battery cells to expand or contract
Data Source
AI summary
A wiring module to be attached to a plurality of power storage devices, including a busbar to be connected to electrode terminals of the plurality of power storage devices, a flexible board, a metal piece connecting the busbar to the flexible board, and an electric wire, in which the flexible board has formed thereon a conductive path having a first land connected to the metal piece, a second land connected to the electric wire, and a fuse portion provided between the first land and the second land, and the flexible board includes a board body and a coupling portion coupling the board body to the metal piece while allowing displacement of the metal piece relative to the board body.