Busbar Module Plate Connector Design for EV Battery Systems
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Solution Overview
Problem
The existing busbar modules for power supply units in hybrid and electric vehicles require multiple molds for production, increasing costs due to the need for separate molds for plates with and without electric wire fixing portions, which complicates the manufacturing process and raises production expenses.
Innovation Solution
A busbar module design that incorporates a connector system with a second connecting piece and a first connecting piece, including a projecting portion and erected wall portions, allows for the connection of plates without applying a load to the electric wires, using a binding band to fix the wires and enable the plates to be molded using a single mold, reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate molds are used for plates with and without electric wire fixing portions, then the electric wires can be properly fixed to the plates, but the production cost increases due to the need for multiple molds
Solution Approach 1:
The patent combines the electric wire fixing portion and the plate into a single integrated component molded from a single piece of resin. This merging eliminates the need for separate molds for plates with and without fixing portions, thereby reducing mold costs while maintaining reliable electric wire fixation through the integrated design of the fixing protrusions and recesses
Solution Approach 2:
The plate is designed with multi-functionality by integrating both the structural support function and the electric wire fixing function into a single component. The fixing protrusions and recesses are built into the plate structure itself, allowing the same plate design to serve both purposes without requiring separate specialized components or molds
2Ease of operation
If the plates are connected by arranging electric wires from one plate to another, then the plates can be electrically connected, but the electric wires are subjected to load when the plates are carried, causing the wires to be pulled from the terminals
Solution Approach 1:
The patent segments the connection function by introducing a dedicated connector component that is separate from the electric wires. The connector includes connection portions that engage with terminals and wire holding portions that secure the wires, thereby separating the mechanical connection function from the electrical connection function and protecting the wires from load during plate carrying
3Reliability
If adhesive tape is used to fix electric wires to the secondary plate, then the wires can be secured to the plate, but the production cost increases and the fixing reliability is insufficient
Solution Approach 1:
The patent extracts the electric wire fixing function from the secondary plate and implements it through dedicated fixing protrusions and fixing recesses that are integrally molded into the plate structure. This extraction eliminates the need for separate adhesive tape applications, providing more reliable mechanical fixing through precise geometric engagement while reducing production costs by eliminating the adhesive tape material and application steps
Data Source
AI summary
In a busbar module for connecting a plurality of batteries of a battery unit, the batteries are arranged so that electrodes of each of the batteries having different polarities are disposed adjacent to each other. The busbar module includes a plurality of busbars, a plurality of terminals, a plurality of wires, a plurality of plates and a connector. The busbars connect the electrodes adjacent to each other. The terminals are connected to the busbars respectively to detect a voltage of the batteries. The wires are connected to the terminals respectively. The plates accommodate the busbar, the terminals and the wires, and provided above the battery unit. The connector connects the plates together.