Flat Cable Busbar Connection via Pressure Welding Blade
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Solution Overview
Problem
Existing electric wire connection structures for flat cables in battery modules require preprocessing, such as cutting notches and separating conductor lines, which complicates the connection process to busbars.
Innovation Solution
An electric wire connection structure that includes a flat cable with insulating conductors and busbars, where a connecting member with a pressure welding blade is used to press-fit into the cable's insulator, allowing direct electrical connection to busbars without prior processing of the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flat cable is processed in advance (cutting notches, separating conductor lines), then the connection to busbars can be achieved, but the manufacturing complexity and processing time increase
Solution Approach 1:
The insulator is designed with pre-formed through-holes at specific positions that correspond to the conductor lines. These through-holes are created in advance during insulator manufacturing, eliminating the need for field processing. The connecting members are also pre-formed with pressing portions that align with these through-holes, enabling direct connection without additional processing steps.
Solution Approach 2:
The insulator's through-holes and the connecting members work together in a self-aligning manner. The pressing portions of the connecting members automatically align with the through-holes during assembly, and the insulator itself facilitates the connection process by providing the necessary access paths, eliminating the need for external processing tools or operations.
2Ease of manufacture
If the flat cable is processed in advance (cutting notches, separating conductor lines), then the connection to busbars can be achieved, but the assembly time and productivity decrease
Solution Approach 1:
All necessary access features (through-holes in insulator, pressing portions on connecting members) are prepared in advance during component manufacturing. This preliminary preparation eliminates the need for time-consuming field processing operations such as cutting, notching, or separating conductor lines during assembly, thereby significantly improving assembly efficiency.
Solution Approach 2:
The connection system is divided into separate functional components: the insulator with through-holes, the connecting members with pressing portions, and the flat cable with conductor lines. This segmentation allows each component to be manufactured independently with pre-formed features, enabling rapid assembly without complex processing operations.
3Ease of manufacture
If the insulator is processed to expose conductors (using laser), then the connection to busbars can be achieved, but the equipment complexity and processing cost increase
Solution Approach 1:
Instead of removing material from the insulator using complex laser equipment, the design extracts the necessary function by forming through-holes that provide access to the conductor lines. The connecting members then directly engage with the conductors through these holes, eliminating the need for laser processing equipment and reducing overall system complexity.
Solution Approach 2:
The through-holes in the insulator serve as intermediaries that facilitate connection between the connecting members and the conductor lines. This intermediary structure provides a simple mechanical path for electrical connection without requiring complex material removal or exposure processes.
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
This solution simplifies the connection process by eliminating the need for preprocessing the flat cable, improving assembly efficiency and ensuring strong, reliable electrical connections between the cable and busbars.
Implementation Method 1
a pressure welding blade portion connected to the connecting member main body, a pressure welding groove being formed on the pressure welding blade portion. Herein, the connecting member allows an inner edge of the pressure welding groove to touch the linear conductors exposed from the insulator due to press-fitting into the pressure welding groove
Data Source
AI summary
A electric wire connection structure includes a flat cable including a plurality of linear conductors and an insulator covering the linear conductors; a plurality of busbars for electrically connecting electrode terminals provided on two or more of battery cells stretched in a given direction among the plurality of battery cells stacked in the direction and included in a battery module, the electrode terminals being lined up in the direction; and connecting members provided for each combination of the linear conductors and the busbars to include a connecting member main body and a pressure welding blade portion connected to the connecting member main body, a pressure welding groove being formed on the pressure welding blade portion.