Flexible Busbar Module for Battery Stack Assembly Variation
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Solution Overview
Problem
Existing busbar modules face challenges in assemblability and adaptability to the deformation and manufacturing variations of battery assemblies, particularly when the number of stacked battery cells increases, leading to increased rigidity and difficulty in coping with thermal expansion and assembly tolerances.
Innovation Solution
A busbar module design featuring a first and second circuit body formed from flexible substrates with specific wiring patterns, connected via a holder that is extensible and contractible, allowing for improved flexibility and adaptability to battery assembly deformations and variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of stacked battery cells is increased to increase battery assembly capacity, then the battery capacity increases, but the number of electric wires increases causing the voltage detection line to become more rigid and assemblability deteriorates
Solution Approach 1:
The patent replaces traditional bundled electric wires with a flexible printed circuit board (FPC) as the voltage detection line. The FPC is formed by patterning a flexible substrate, allowing it to maintain flexibility even when connecting multiple battery cells. This resolves the contradiction by providing a flexible connection structure that can adapt to increased battery capacity without becoming rigid like bundled wires would.
Solution Approach 2:
The patent substitutes the mechanical bundling structure of multiple electric wires with a planar flexible circuit board structure. The FPC uses printed conductive patterns on a flexible substrate instead of mechanically bundling individual wires, eliminating the rigidity issue that arises from wire bundling while maintaining electrical connectivity for voltage detection across multiple cells.
2Reliability
If the voltage detection line is formed by bundling many electric wires to monitor all battery cells, then the voltage detection coverage increases, but the rigidity of the voltage detection line increases making it difficult to cope with deformation and manufacturing variation
Solution Approach 1:
The FPC structure allows the voltage detection line to flex and deform with the battery assembly. The flexible substrate can accommodate thermal expansion, contraction, and manufacturing variations without compromising the electrical connection or detection capability, thus maintaining adaptability while ensuring comprehensive voltage monitoring.
Solution Approach 2:
The flexible circuit board provides a dynamic connection structure that can adapt its shape and length to match the deformed state of the battery assembly. Unlike rigid wire bundles, the FPC can dynamically adjust to dimensional changes in the battery pack while maintaining reliable electrical contact for voltage detection.
3Adaptability or versatility
If a certain margin in the length of the voltage detection line is designed to cope with deformation and manufacturing variation, then the adaptability to deformation improves, but when the number of battery cells increases the overall length increases causing the bundled wire structure to become more rigid
Solution Approach 1:
The FPC structure inherently provides flexibility throughout its entire length, allowing it to accommodate deformation margins without increasing rigidity. The flexible substrate material and printed circuit design enable the voltage detection line to bend and flex along its entire length, maintaining adaptability even when the overall length increases to accommodate more battery cells.
Data Source
AI summary
A busbar module includes: a first circuit body formed of a flexible substrate and including a first main line portion and a first branch line portion; a second circuit body that is formed of a flexible substrate having a second wiring pattern and that includes a second main line portion and a second branch line portion; an electronic component; and a holder. The first and second wiring patterns are electrically connected to each other at an overlapping portion of the first and second main line portions.