Flexible Bus Bar Layout for Battery Pack Position Tolerance
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Solution Overview
Problem
Conventional bus bar modules face challenges in reducing height while absorbing positional variations of battery packs due to deformation and manufacturing tolerances, often requiring an S-shaped folding structure that increases height.
Innovation Solution
A bus bar module with a flexible substrate and belt-shaped main body featuring overlapping bus bar portions that can deform to absorb positional variations without increasing height, allowing for a more compact design by using a single-sided flexible substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the bus bar branch strip is folded into an S-shape in the vertical direction to absorb positional variations, then the positional variations are accommodated, but the height of the bus bar module increases
Solution Approach 1:
The bus bar branch strip is configured to extend in the width direction of the battery pack rather than folding vertically. This dimensional shift allows positional variation absorption through lateral extension and overlap with the main body, avoiding vertical height increase while maintaining adaptability to positional variations
Solution Approach 2:
The bus bar branch strip overlaps with the main body of the bus bar module in the width direction, creating a nested configuration. This nesting allows the branch strip to extend laterally for position absorption while being partially contained within the overall module footprint, preventing height increase
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 solution effectively absorbs positional variations of battery packs in all directions, reducing the overall height of the bus bar module and enabling its placement in narrow spaces while maintaining manufacturing cost efficiency.
Implementation Method 1
a circuit body composed of a flexible substrate provided with a circuit wiring, and the circuit body has a belt-shaped main body extending in a predetermined direction and a plurality of bus bar portions arranged at a distance in an extending direction of the main body, and at least a part of the bus bar portions is arranged to overlap with the main body
Data Source
AI summary
The bus bar module includes a circuit body composed of a flexible substrate provided with a circuit wiring. The circuit body includes a belt-shaped main body extending along a predetermined direction and a plurality of bus bar portions arranged at a distance in an extending direction of the main body. At least a part of the bus bar portions is arranged to overlap with the main body.