Segmented Battery Wiring Module for High-Capacity EV Packs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing battery wiring modules for high-voltage battery packs in electric and hybrid automobiles face challenges in workability due to long sensing busbars, which complicate the assembly process as the battery cells increase in size and power storage capacity.
Innovation Solution
A battery wiring module design featuring separate first and second busbar modules with flexible printed circuit boards and protectors, allowing for improved handling and connection efficiency by enabling separate attachment and electrical connection of the modules to the battery cells, reducing the length of the flexible printed circuit boards, and incorporating a thermistor circuit for temperature detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the sensing busbar is made long to connect battery cells with increased power storage capacity, then the battery cell can achieve higher power storage capacity, but the workability in the assembling process is significantly decreased
Solution Approach 1:
The busbar unit is divided into a first busbar module and a second busbar module that are separate components. The first busbar module includes first busbars connected to electrode leads protruding frontward, while the second busbar module includes second busbars connected to electrode leads protruding rearward. This segmentation allows each module to be handled separately during assembly, improving workability while maintaining the ability to connect battery cells with higher power storage capacity.
2Quantity of substance
If the sensing busbar is made long to connect battery cells with increased power storage capacity, then the battery cell can achieve higher power storage capacity, but the handling of the busbar unit is not good
Solution Approach 1:
The busbar unit is segmented into separate first and second busbar modules. Each module can be held and positioned independently during assembly, significantly improving handling characteristics compared to a single long integrated busbar unit.
Solution Approach 2:
A sensing wire acts as an intermediary component that connects the first busbar module and the second busbar module. This allows the modules to be handled separately while still achieving the electrical connection function of a long sensing busbar.
3Quantity of substance
If the sensing busbar is made long, then it can connect battery cells with increased power storage capacity, but the workability in the assembling process of mounting the busbar unit is highly decreased
Solution Approach 1:
The busbar unit is divided into separate first and second busbar modules that can be manufactured and assembled independently. This segmentation simplifies the assembly process by allowing workers to handle smaller, more manageable components rather than a single long busbar unit.
Solution Approach 2:
The first and second busbar modules can be prepared and positioned separately before final assembly. The sensing wire can be preliminarily connected to one module before the other module is attached, making the overall assembly process more manageable and less complex.
Data Source
AI summary
A battery wiring module is to be attached to multiple battery cells being long in a front-rear direction and including electrode leads at front ends and rear ends of the multiple battery cells to electrically connect the multiple battery cells. The battery wiring module includes a first busbar module to be attached to a front section of the multiple battery cells and a second busbar module that is a separate component from the first busbar module and to be attached to a rear section of the multiple battery cells. The first busbar module includes first busbars that are to be connected to the electrode leads protruding frontward from the multiple battery cells, a first flexible printed circuit board that is to be connected to the first busbars, and a first protector that holds the first busbars and the first flexible printed circuit board.