Busbar Holder Roller Path for Flexible Circuit 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, allowing it to extend along a bent path and accommodate cell expansion, and includes rollers and elastic members to maintain electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If battery cells are used for charging and discharging, then energy storage and power output are improved, but the battery cells expand during charging which causes sensor disconnection from the flexible circuit
Solution Approach 1:
The flexible circuit part is designed to be dynamically adjustable in length through the length adjuster mechanism. As battery cells expand during charging, the flexible circuit can extend or retract along its bent path between the first and second rollers, maintaining continuous electrical connection between sensors and the FPC while accommodating the volume changes of the battery cells
Solution Approach 2:
The length adjuster acts as an intermediary mechanism between the battery cells and the flexible circuit part. It includes a first elastic member that elastically presses the first roller to enable the flexible circuit to extend along a bent path, and a tension adjuster with a tension roller that moves in response to tension changes in the flexible circuit, thereby mediating the mechanical stress and preventing disconnection
2Reliability
If the flexible circuit part is made straight to maintain connection, then electrical connection reliability is improved, but it cannot accommodate the expansion of battery cells
Solution Approach 1:
The flexible circuit part transitions from a fixed straight configuration to a dynamic bent configuration that can adjust its effective length. The length adjuster enables the circuit to extend or retract along the bent path defined by the rollers, providing both reliable electrical connection and adaptability to battery cell expansion
Solution Approach 2:
The system changes the geometric parameters of the flexible circuit path by introducing a bent configuration with rollers. The first elastic member and tension adjuster modify the position and curvature of the bent path, allowing the flexible circuit to accommodate varying lengths required during battery cell expansion while maintaining electrical connection
3Stability of the object's composition
If a rigid structure is used to hold the flexible circuit, then structural stability is improved, but it prevents the circuit from accommodating expansion and maintains connection
Solution Approach 1:
The support structure for the flexible circuit is designed with dynamic elements including rollers that can move along the circuit path and elastic members that provide flexible support. This dynamic structure maintains stability while allowing the flexible circuit to extend and retract, preventing disconnection during battery cell expansion
Solution Approach 2:
The flexible circuit part itself acts as a flexible element that can bend and extend along a curved path. The length adjuster mechanism uses this flexibility to its advantage, allowing the circuit to accommodate expansion while the roller-based support system provides stable guidance and tension control
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 effective 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
a tension adjuster including a tension roller which is located between a pair of bent path parts spaced apart from each other among the plurality of bent path parts, is in contact with the flexible circuit part, and is movable by tension of the flexible circuit part
Implementation Method 3
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
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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.