Flexible Bus Bar Fold Structure to Prevent Laminate Separation

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Solution Overview

Problem

Conventional bus bars made of laminated metal plates can separate during manufacturing if not properly grouped, leading to dimensional tolerance issues in power storage packs.

Innovation Solution

A flexible bus bar design featuring at least one folded portion and multiple laminated portions, where side edges of the laminated portions include cut portions to prevent separation during manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple metal plate members are laminated to form a flexible bus bar, then the bus bar can bend and deform to accommodate dimensional tolerance between batteries, but the metal plate members may separate from each other during manufacturing

Engineering Contradiction:

Improvedimensional tolerance accommodationVSAvoidmetal plate member separation

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The invention divides the metal plate member into multiple laminated portions (first, second, third laminated portions) that are stacked in the thickness direction. Each portion can independently deform while maintaining connection through folded portions, enabling the structure to accommodate dimensional tolerance through segmented deformation rather than requiring the entire bus bar to deform uniformly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention implements a nested structure where multiple laminated portions are stacked in the thickness direction with folded portions connecting them. The folded portions act as hinges that allow each laminated portion to rotate relative to adjacent portions, creating a nested deformation mechanism that accommodates dimensional variations while keeping the layers connected.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of manufacture

If metal plate members are laminated without grouping tweaks during manufacturing, then the manufacturing process is simpler, but the metal plate members separate from each other

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidmetal plate member separation

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The invention incorporates folded portions and cut portions as pre-designed structural features before the lamination process. The folded portions create natural connection points that prevent separation during manufacturing without requiring additional grouping operations. The cut portions remove excess material that could interfere with lamination, enabling simple stacking of pre-prepared metal plate portions.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the bus bar structure is made flexible through lamination, then it can handle dimensional tolerance, but the structure becomes more complex

Engineering Contradiction:

Improvedimensional tolerance handlingVSAvoidbus bar structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention applies folded portions and cut portions only at specific locations where flexibility is needed, rather than making the entire bus bar structure complex. The laminated portions maintain simple flat structures in most areas, with localized folding and cutting only where dimensional tolerance accommodation is required, thus minimizing overall structural complexity.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12278394B2Flexible bus bar, composite bus bar, power storage pack, and method for manufacturing flexible bus bar

Publication Date: 2025.04.15 AUTONETWORKS TECH LTD

AI summary

Provided is a flexible bus bar including at least one folded portion in which one metal member is folded, and a plurality of laminated portions laminated via the folded portion, in which side edges of the plurality of laminated portions provided with the folded portion is formed include a cut portion in which a portion other than the folded portion has been cut.