Busbar Module Holding Member Prevents Flat Cable Sagging
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Solution Overview
Problem
The flexibility of flat cables in busbar modules can lead to sagging during assembly, complicating the assembly process of battery packs in electric vehicles, which affects workability and increases the risk of erroneous assembly.
Innovation Solution
A busbar module with a holding member that includes a flexible flat conductor and an insulating holding portion, featuring a hinge portion and lock mechanism to securely attach and cover the busbars, allowing for improved assembly and insulation while accommodating design tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible flat cables are used to connect busbars, then the busbar module can accommodate design tolerances and assembly variations, but the cables may sag during assembly which complicates the assembly process and reduces workability
Solution Approach 1:
The holding member is designed to preliminarily hold and position the flexible flat cable in a taut state before assembly is completed. The holding bodies with insertion portions and locking structures secure the cable at multiple points along its length, preventing sagging during the assembly process while still allowing the cable to accommodate design tolerances in the final assembled state.
Solution Approach 2:
The holding member acts as an intermediary component between the busbars and the flexible flat cable. It provides a structured framework that maintains cable tension and position, mediating between the need for cable flexibility to accommodate tolerances and the need for stability during assembly operations.
2Manufacturing precision
If multiple separate holding operations are performed for each busbar, then precise positioning can be achieved, but the number of assembly operations increases which reduces productivity
Solution Approach 1:
Multiple holding functions for individual busbars are merged into a single integrated holding member structure. The holding member simultaneously holds multiple busbars and the flexible flat cable through multiple holding bodies that are structurally connected, allowing all positioning operations to be performed in one assembly action rather than multiple separate operations.
Solution Approach 2:
The holding member is designed as a multi-functional component that simultaneously performs multiple positioning and holding functions. It holds busbars in correct positions, secures the flexible flat cable at multiple points, and maintains proper spacing and alignment, all within a single assembly operation.
Data Source
AI summary
A busbar module includes a basic busbar module assembled to an electrode terminal group arranged in a row of a battery module formed of a plurality of battery cells, and a holding member that holds the basic busbar module. The basic busbar module includes a plurality of busbars that is arranged along an arrangement direction of respective electrode terminals of the electrode terminal group and is electrically connected to the corresponding electrode terminals, and flat cable having a conductor portion that is electrically connected to the plurality of busbars, and an insulating holding portion that holds the plurality of busbars, and the holding member has a holding body that holds the basic busbar module.