Busbar Holder With Flexible Circuit Length Adjustment for Cell Expansion
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Solution Overview
Problem
Battery sensors in a module can become electrically disconnected due to expansion of battery cells, preventing the monitoring of the battery state.
Innovation Solution
A busbar holder with a length adjuster that supports a flexible circuit part to maintain electrical connection by allowing it to extend along a bent path, using rollers and elastic members to accommodate cell expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are used for energy storage and charging/discharging operations, then the battery module provides power and capacity, but the battery cells expand during charging which causes sensor locations to change and leads to electrical disconnection from the flexible printed circuit
Solution Approach 1:
The patent employs a dynamic length adjuster mechanism comprising rollers and elastic members that can dynamically adjust the path length of the flexible printed circuit. This dynamic adjustment capability allows the system to accommodate the expansion and contraction of battery cells during charging and discharging cycles, maintaining continuous electrical connection between sensors and the flexible printed circuit despite changes in battery cell dimensions.
Solution Approach 2:
The patent utilizes elastic members that undergo parameter changes through elastic deformation. These elastic members can extend and contract in response to battery cell expansion, thereby changing the effective length of the flexible printed circuit path. This parameter change mechanism ensures that the electrical connection is maintained while accommodating the physical expansion of battery cells during operation.
2Reliability
If the flexible circuit part is made rigid to maintain stable electrical connection, then connection stability is improved, but the circuit cannot accommodate battery cell expansion and becomes disconnected
Solution Approach 1:
The patent employs a flexible printed circuit instead of a rigid circuit board. This flexible circuit can bend and deform to accommodate the expansion of battery cells while maintaining electrical connection. The flexibility of the circuit allows it to adapt to changing spatial requirements without compromising connection stability.
Solution Approach 2:
The length adjuster mechanism with rollers and elastic members creates a dynamic system that can adjust the effective length of the flexible circuit path. This dynamic adjustment allows the system to maintain stable electrical connection while adapting to battery cell expansion, combining connection reliability with adaptability.
3Ease of operation
If sensors are placed at fixed locations to monitor battery state, then monitoring is simplified, but sensor locations change due to battery expansion causing disconnection
Solution Approach 1:
The dynamic length adjuster mechanism compensates for the displacement of sensors caused by battery cell expansion. By dynamically adjusting the path length of the flexible printed circuit, the system maintains continuous electrical connection between sensors and the circuit, ensuring reliable monitoring despite changes in sensor locations.
Solution Approach 2:
The elastic members in the length adjuster mechanism provide beforehand cushioning by being pre-loaded with elastic force. This pre-loaded elasticity allows the mechanism to immediately respond to and compensate for battery cell expansion, preventing disconnection before it occurs and ensuring continuous sensor connection.
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
Ensures continuous electrical connection of sensors to the flexible circuit, enabling reliable monitoring of battery state despite cell expansion.
Implementation Method 1
a first elastic member which elastically presses the first roller in a direction in which the first roller is moved away from the second roller
Implementation Method 2
an elastic tension roller pressing member which elastically presses the tension roller in an increase direction of the tension of the flexible circuit part
Data Source
AI summary
A busbar holder and a battery module are disclosed. A busbar holder includes a holder plate which supports a plurality of busbars electrically connecting a plurality of battery cells and a length adjuster supported by the holder plate and supporting a flexible circuit part configured to transmit an electric signal generated by measuring a state of the battery cells such that the flexible circuit part extends along a bent path.