Deformable Busbar Connector for Battery Module Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power distribution components in motor vehicles face challenges such as space constraints, harsh operating conditions, vibrations, and temperature fluctuations, leading to connector failures and significant repair and warranty costs.
Innovation Solution
An elastically deformable connector system with a busbar having a deformable intermediate portion between peripheral portions, designed to compensate for material conditions and dynamic movement of battery modules due to charging, discharging, temperature changes, and other factors, using a busbar with fused and unfused segments to accommodate expansion and contraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid connector system is used to ensure stable electrical connection, then connection stability is improved, but the system cannot accommodate dynamic movement and material expansion/contraction of battery modules, leading to connector failure
Solution Approach 1:
The busbar incorporates a deformable intermediate portion that can dynamically change its shape and position to accommodate expansion and contraction of battery modules during charging and discharging cycles, while maintaining stable electrical connection at the peripheral portions
Solution Approach 2:
The busbar is divided into distinct functional segments: rigid peripheral portions for stable connection and a flexible intermediate portion for accommodation of movement, allowing each segment to perform its specific function optimally
2Ease of manufacture
If conventional rigid power distribution components are used, then manufacturing and installation are straightforward, but the components fail under harsh operating conditions including vibrations, temperature fluctuations, and space constraints
Solution Approach 1:
The busbar's intermediate portion is designed with specific geometric parameters (curvature radius, length, cross-section) that enable it to withstand vibrations and temperature fluctuations while maintaining electrical connection, transforming the component from rigid to adaptively flexible
3Reliability
If the busbar is made completely rigid to ensure stable connection, then electrical connection reliability is improved, but the system cannot compensate for material conditions and dynamic movement, resulting in connector failure
Solution Approach 1:
Different portions of the busbar have different mechanical properties: peripheral portions are rigid for stable connection while the intermediate portion is flexible for movement accommodation, with each portion optimized for its specific function
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
The connector system improves reliability and performance by minimizing failure modes, enhancing the operating life of battery modules and packs by allowing for elastic deformation to accommodate dynamic movements.
Implementation Method 1
the intermediate portion is capable of elastically deforming to compensate for each of compression movement and expansion movement of the pair of battery modules
Data Source
AI summary
An elastically deformable connector system for use in connecting battery modules in a battery pack. The elastically deformable connector system comprising busbar assembly having a busbar with a plurality of individual conductors vertically arranged to provide a first peripheral portion, a second peripheral portion, and an elastically deformable intermediate portion located between the first and second peripheral portions. The busbar assembly also includes a first male connector assembly coupled to the first peripheral portion of the busbar, a second male connector assembly coupled to the second peripheral portion of the busbar, and a busbar housing that encloses a substantial extent of the busbar. Wherein after the busbar assembly is electrically connected to a pair of battery modules in the battery pack, the intermediate portion is configured to elastically deform to compensate for each of compression movement and expansion movement of the pair of battery modules.