Foldable Busbar Module Structure for Compact Battery Pack Shipping
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Solution Overview
Problem
Conventional busbar modules in power supply devices for vehicles increase in size due to the growing electric power requirements, leading to larger packaging sizes and increased transportation costs.
Innovation Solution
A busbar module with a case divided into sections that can be rotated into a folded state, allowing the sections to overlap, reducing the overall size when not in use, and expand to a flat state for operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of single cells is increased to meet growing electric power requirements, then the power supply capacity is improved, but the busbar module size increases in the longitudinal direction
Solution Approach 1:
The case is divided into multiple divided cases (first divided case, second divided case, third divided case) that can be independently positioned. This segmentation allows the busbar module to be configured in different spatial arrangements, enabling compact folding configurations that reduce packaging size while maintaining the capacity to accommodate multiple single cells for high power supply requirements.
Solution Approach 2:
The connection structure enables the divided cases to be rotatable relative to each other, transitioning between a folded state for compact storage and an expanded state for operational use. This dynamic capability allows the same structure to accommodate varying numbers of single cells while optimizing both packaging efficiency and power supply capacity.
2Power
If the busbar module size increases to accommodate more single cells, then the power supply capacity is improved, but the packaging size increases leading to higher transportation costs
Solution Approach 1:
The rotatable connection structure enables the busbar module to transition between folded and expanded states, allowing compact packaging for transportation while maintaining full operational capacity when deployed. This dynamic configuration resolves the contradiction between power supply capacity and packaging volume by optimizing the spatial arrangement based on operational requirements.
Solution Approach 2:
In the folded state, the divided cases are positioned to overlap each other in a nested arrangement, significantly reducing the packaging volume. This nesting principle allows the busbar module to be compacted for efficient transportation and storage, while the same structure expands to accommodate multiple single cells for high power applications.
3Volume of stationary object
If the busbar module is designed for compact folding, then the packaging size is reduced, but the structural complexity increases due to rotatable connection structures
Solution Approach 1:
The case is divided into modular divided cases that can be independently positioned and connected. This segmentation simplifies the overall structure by breaking down the complex folding mechanism into discrete, manageable units that can be easily assembled and maintained, reducing the practical complexity despite the dynamic functionality.
Solution Approach 2:
The rotatable connection structure provides a straightforward mechanical mechanism for achieving compact folding. By using simple rotational joints between divided cases, the design achieves compact packaging without requiring complex actuation systems, maintaining structural simplicity while enabling dynamic configuration changes.
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 busbar module can be compactly stored in a folded state, reducing transportation costs and maintaining efficient electrical connectivity when expanded.
Implementation Method 1
a connection structure rotatably connecting adjacent divided cases of the plurality of divided cases with each other
Data Source
AI summary
A busbar module that can be brought into a folded state and a busbar module attachment method. The busbar module includes a case configured to be installed on the battery assembly, a plurality of busbars supported by the case and configured to be respectively connected to single cells, and a routing material electrically connected to the busbars and routed in the case. The case includes a plurality of divided cases that are divided in a direction in which the single cells are arranged, and a connection structure connecting adjacent divided cases of the divided cases with each other. The connection structure displaces the divided cases into a folded state in which the divided cases are rotated so that adjacent divided cases overlap each other and an expanded state in which the divided cases are situated on a same plane.