Split Busbar Module for Battery Pack Pitch Tolerance
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Solution Overview
Problem
Existing battery modules face challenges in absorbing pitch shifts between electrode terminals due to assembly tolerances and temperature-induced expansion, leading to increased dimensions and voltage detecting wire breadth, which contradicts the need for downsizing in electric vehicle and hybrid vehicle battery packs.
Innovation Solution
A busbar module comprising split busbar modules with integrated busbars and split flat cables of varying lengths, where the split flat cables are overlapped and connected by resin portions, allowing for adjustable pitch absorption without increasing the battery pack's dimensions, and the busbars are connected by resin to maintain handling ease and prevent fluttering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of battery cells is increased to increase output, then the power increases, but the dimension of the battery pack increases
Solution Approach 1:
The battery pack is divided into multiple battery modules, each containing a specific number of battery cells arranged in series. This segmentation allows the overall output to be increased by adding more modules rather than continuously enlarging a single module, thereby managing the dimension growth.
Solution Approach 2:
The battery cells within each module are arranged in a three-dimensional configuration rather than a simple linear extension. By utilizing vertical stacking and layered arrangements, the patent increases power output without proportionally increasing the horizontal footprint of the battery pack.
2Adaptability or versatility
If the breadth of flat cable is increased to accommodate more voltage detecting wires, then the number of detectable battery cells increases, but the dimension of the battery pack increases
Solution Approach 1:
The voltage detecting system is segmented into multiple independent flat cables, each serving a specific battery module. Instead of using one large flat cable to detect all battery cells, the patent divides the detection function across multiple smaller cables, reducing the breadth requirement while maintaining adaptability.
Solution Approach 2:
A resin portion acts as an intermediary material that integrates the flat cable with the busbar module structure. This integration allows the flat cable to be securely positioned and connected without requiring additional space, thereby maintaining compact dimensions while supporting multiple voltage detecting wires.
3Adaptability or versatility
If the pitch between electrode terminals is shifted due to tolerance accumulation, then the assembly flexibility increases, but the connection reliability decreases
Solution Approach 1:
The design incorporates built-in tolerance compensation mechanisms that anticipate and accommodate pitch variations before they affect connection reliability. The busbar module structure includes adjustable elements and flexible connections that can absorb dimensional variations, ensuring reliable electrical connections despite assembly tolerances.
Solution Approach 2:
The patent employs parameters such as flexible connection geometries and adjustable mounting positions that can be varied to accommodate pitch shifts. By changing these geometric parameters, the system maintains reliable electrical connections even when the pitch between electrode terminals deviates from nominal values due to tolerance accumulation.
Data Source
AI summary
Provided is a busbar module including a plurality of split busbar modules that are configured such that a busbar group including a plurality of busbars and split flat cable including a plurality of linear conductors are integrated at one end side in a longitudinal direction of the split flat cables. The plurality of split busbar modules include split flat cables having a length different from each other and are configured such that the split flat cables are overlapped with each other and the busbar groups are respectively arranged in the same direction.