Busbar Module Layout Using Flexible Wiring to Cut Pack Area
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Solution Overview
Problem
Conventional busbar modules occupy a large area, which interferes with other components and increases the profile of battery packs, necessitating a reduction in the exclusive area covered by the busbar module.
Innovation Solution
A busbar module design featuring a first and second busbar group aligned in parallel, connected by a flexible printed wiring board with a T-shaped slit, and a case with flexible hinges that allows the busbar groups to be covered, minimizing the area occupied and enabling efficient assembly without interfering with other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a conventional busbar module design is used, then electrical connections are ensured, but the exclusive area occupied is large
Solution Approach 1:
The busbar module is divided into a first busbar group and a second busbar group, which are arranged in parallel and connected through a flexible printed wiring board. This segmentation allows the module to occupy less area while maintaining electrical connection reliability through the wiring board's conductive paths.
Solution Approach 2:
The busbar groups are arranged in parallel in the second direction rather than extending in the first direction, effectively utilizing the second dimension for spatial arrangement. This dimensional change reduces the exclusive area occupied by the module while preserving all necessary electrical connections.
2Area of stationary object
If the busbar module area is reduced, then interference with other components is reduced, but assembly complexity increases
Solution Approach 1:
The flexible printed wiring board serves multiple functions simultaneously: it provides electrical connections between busbars, acts as a structural support element, and enables the parallel arrangement of busbar groups. This merging of functions reduces the need for additional components, thereby simplifying the overall module structure despite the compact area.
Solution Approach 2:
The flexible printed wiring board is designed to perform multiple roles within the module, including electrical conduction, mechanical support, and spatial positioning of busbar groups. This multi-functionality reduces the total component count and simplifies assembly processes while achieving the reduced area objective.
3Area of stationary object
If busbar groups are arranged in parallel, then exclusive area is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The flexible printed wiring board acts as an intermediary element between the first and second busbar groups, providing a standardized interface for electrical connections. This intermediary component establishes precise connection points and alignment references, thereby reducing the overall manufacturing precision requirements for the busbar group arrangement.
Solution Approach 2:
The design allows for flexibility in the positioning and dimensions of the busbar groups while maintaining electrical connection integrity through the wiring board. By changing certain geometric parameters and allowing tolerances in the parallel arrangement, the manufacturing precision requirements are reduced while still achieving the area reduction goal.
Data Source
AI summary
A busbar module includes a first busbar group, a second busbar group, a flexible printed wiring board, and a case made of resin. The flexible printed wiring board includes a base end and a main body. The flexible printed wiring board includes a first slit portion and a second slit portion. The main body is divided by the second slit portion into two regions, a first region and a second region. The case includes a first case portion and a second case portion. The first case portion is configured so that the first region and the first cover cover the first busbar group. The second case portion is configured so that the second region and the second cover cover the second busbar group.