Flexible Bus Bar Line for Battery Module Terminal Pitch Adjustment
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Solution Overview
Problem
Battery modules for electric cars and hybrid cars face inefficiencies due to non-constant pitches between electrode terminals, leading to misalignment and reduced operational efficiency, which existing connecting methods struggle to compensate for changes caused by cell shrinkage or expansion.
Innovation Solution
A battery module design featuring a belt-shaped bus bar line with flexible flat cables that include folded portions to adjust for non-constant terminal pitches, serving both as a connector and voltage detecting line, and using resin-made separators to prevent short circuits, reducing the need for additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a battery connecting plate with integrally-molded connecting members is used to connect electrode terminals, then the operational efficiency is enhanced by collectively connecting multiple inter-terminal spaces, but the positional misalignment occurs when pitches between electrode terminals are non-constant due to assembly tolerance
Solution Approach 1:
The connecting members are designed with flexible portions that can dynamically adjust their position to accommodate non-constant pitches between electrode terminals. This flexibility allows the rigid portions to maintain secure electrical connections while the flexible sections absorb positional variations, resolving the contradiction between efficient collective connection and precise positional alignment.
Solution Approach 2:
The connecting members incorporate variable stiffness characteristics by changing their physical parameters along their length - rigid portions for secure connection and flexible portions for adaptation. This parameter variation enables the same component to achieve both stable electrical contact and tolerance compensation, addressing the alignment issue while maintaining operational efficiency.
2Reliability
If the battery connecting plate is designed with fixed structure to ensure stable connection, then the connection reliability is improved, but the inability to compensate for pitch non-constancy due to cell shrinkage or expansion occurs
Solution Approach 1:
The connecting members transition from a completely fixed structure to a dynamic structure with flexible portions that can adapt to pitch variations caused by cell shrinkage or expansion. The flexible sections act as shock absorbers, maintaining reliable electrical connection while accommodating dimensional changes in the battery cells over time.
Solution Approach 2:
The flexible portions in the connecting members serve as pre-designed cushioning elements that anticipate and absorb the effects of cell shrinkage or expansion before they cause connection failure. This beforehand cushioning ensures that the rigid connection portions remain stable while the flexible sections compensate for dimensional changes, maintaining reliability throughout the battery's operational life.
3Adaptability or versatility
If multiple separate connecting members are used to connect each electrode terminal pair, then the adaptability to non-constant pitches is improved, but the operational efficiency decreases due to cumbersome repeated connection operations
Solution Approach 1:
Multiple separate connecting members are merged into a single integrated battery connecting plate with multiple connecting members that are collectively attached to the electrode terminals. This merging maintains the pitch adaptation capability of individual connecting members while enabling simultaneous connection of multiple terminal pairs in one operation, thus improving operational efficiency without sacrificing adaptability.
Solution Approach 2:
The battery connecting plate serves as a universal component that performs multiple functions: it provides individual pitch adaptation for each connecting member while simultaneously achieving collective connection of multiple electrode terminal pairs. This multi-functionality resolves the contradiction by combining the adaptability of separate components with the efficiency of an integrated assembly approach.
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 allows for easy adjustment of terminal pitch non-constancy, reduces component count, and prevents short circuits, enhancing operational efficiency and cost-effectiveness by integrating the voltage detecting function into the bus bar line.
Implementation Method 1
a first insulating resin portion formed by heat laminating a film made of an insulating resin, the first insulating resin portion connecting the plurality of bus bars
Implementation Method 2
the portions of the flexible flat cable to be disposed between the adjacent connecting members are provided with the folded members formed by folding the flexible flat cable at the folded lines
Implementation Method 3
a resin-made separator provided between the electric cells adjacent to each other, the separator having a projection projecting outward from an outer wall surface of the battery containers
Data Source
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AI summary
A belt-shaped bus bar line is disposable on a plurality of transversely juxtaposed electric cells in the direction in which the cells are juxtaposed, each electric cell having positive and negative electrode terminals; the bus bar line comprises: a plurality of bus bars (20A, 20B) for electrically connecting the electrode terminals of electric cells adjacent to each other, a first insulating resin portion (22A) formed by heat laminating a film made of an insulating resin, the first insulating resin portion (22A) connecting the plurality of bus bars (20A, 20B) ; and a projection disposing clearance (23) provided between the adjacent bus bars (20A, 20B), such that a projection of a separator is disposable in the projection disposing clearance (23).