Conductive Member Module Busbar Folding for Battery Pack Durability
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Solution Overview
Problem
Conductive connections between flat cables and conductive members in battery packs are prone to durability issues due to expansion and contraction caused by temperature changes and external forces, leading to potential disconnection.
Innovation Solution
A conductive member module with a flat cable and busbars, where the busbars have a plate-shaped main body and a conductor holding part that is folded back to securely hold the conductor closer to the base end side than the welded area, providing additional support and stability against external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductor is connected to the conductive member by welding only, then the connection is simple and easy to manufacture, but the durability is poor due to expansion and contraction caused by temperature changes and external forces
Solution Approach 1:
The conductive member is divided into two functional parts: a plate-shaped main body for welding to the conductor, and a separate conductor holding part formed by cutting and folding back portions of the main body. This segmentation allows each part to perform its specific function optimally - the main body provides welding surface while the folded holding part provides mechanical constraint against external forces.
Solution Approach 2:
The conductor holding part and the main body are merged into a single integrally formed conductive member. The holding part is created by cutting and folding back portions of the main body itself, eliminating the need for separate fastening components while providing both welding functionality and mechanical holding capability in one unified structure.
2Reliability
If the conductor holding part is added to the conductive member, then the durability against external forces is improved, but the manufacturing complexity increases
Solution Approach 1:
The conductor holding part is formed by cutting and folding back portions of the main body during the manufacturing process, before the actual welding operation. This preliminary shaping of the holding part integrates the constraint function into the base manufacturing process, avoiding the need for additional fastening components and their associated assembly steps.
3Strength
If the conductor is held only at the welded part, then the structure is simple, but the connection cannot withstand external forces from cable expansion and contraction
Solution Approach 1:
The conductor holding part extends the constraint function from the welding interface into the longitudinal dimension of the conductor. By folding back portions of the main body to contact the conductor at a position away from the welding part, the solution adds spatial dimensionality to the holding mechanism, creating a distributed constraint system that resists external forces more effectively.
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
Enhances the durability and stability of the connection between the conductive members and the flat cable, preventing conduction failures and maintaining the connected state even under external forces and temperature changes.
Implementation Method 1
the main body being connected to a portion of each of the conductors exposed from the coating by welding
Data Source
AI summary
A conductive member module includes a flat cable that includes a plurality of conductors and an insulating coating covering the conductors, a distal end part of each of the conductors being exposed from the coating, and a plurality of conductive members each of which includes a plate-shaped main body and a conductor holding part, the main body being connected to a portion of each of the conductors exposed from the coating by welding, the conductor holding part being separated from the main body at other sides except for one side connected to the main body by cutting in the main body and being folded back toward the main body to hold a portion of each conductor closer to a base end side than a part welded to the main body, the conductive members being continuously arranged along an extending direction of the flat cable.