Stretchable Busbar Circuit Layout for Battery Cell Tolerance
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Solution Overview
Problem
Existing busbar modules lack sufficient followability to busbars, particularly in cases of positional deviations, which can lead to connectivity issues and increased module height due to the need for bending branch portions.
Innovation Solution
A busbar module design featuring a flexible circuit body with stretchable branch portions that include slits or cutouts, allowing detection lines to be routed along these features, enabling the module to absorb positional deviations and reduce height by stretching rather than bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the circuit body is made rigid to maintain structural stability, then manufacturing precision is improved, but followability to busbars deteriorates
Solution Approach 1:
The circuit body is divided into a rigid main line portion and flexible branch portions. The branch portions include stretchable sections with slits or cutouts that can deform independently to accommodate busbar positional deviations, while the main line portion maintains structural stability for precise manufacturing and assembly.
Solution Approach 2:
Different parts of the circuit body have different mechanical properties. The main line portion is designed with rigid characteristics for stability, while specific branch portions are designed with flexible characteristics including slits or cutouts to provide followability and absorb positional tolerances of busbars.
2Adaptability or versatility
If the branch portion is made flexible to improve followability, then adaptability to busbar position deviations is improved, but manufacturing precision deteriorates
Solution Approach 1:
The circuit body is segmented into a rigid main line portion for precise positioning and manufacturing, and flexible branch portions with slits or cutouts that provide followability. This segmentation allows each part to optimize its function without compromising the other.
Solution Approach 2:
Flexibility is localized to specific branch portions that require followability, while the main line portion maintains rigid properties for manufacturing precision. The slits or cutouts are strategically placed only where needed to absorb positional tolerances.
3Strength
If the circuit body is designed without slits or cutouts to maintain structural integrity, then strength is improved, but followability to busbars deteriorates
Solution Approach 1:
The circuit body is divided into regions with different structural characteristics. The main line portion maintains continuous structure for strength, while branch portions include slits or cutouts to enable deformation and followability without compromising overall structural integrity.
Solution Approach 2:
Structural modifications such as slits or cutouts are applied locally to branch portions that require followability, while the main line portion retains its continuous, strong structure. This localized modification maintains overall strength while providing necessary flexibility.
4Length of stationary object
If the module height is reduced by eliminating bending of branch portions, then compactness is improved, but followability deteriorates
Solution Approach 1:
The branch portions are designed with dynamic flexibility through slits or cutouts, allowing them to stretch and deform to accommodate busbar positional deviations. This dynamic capability eliminates the need for bending, thereby reducing module height while maintaining followability.
Solution Approach 2:
The mechanical parameters of the branch portions are changed by introducing slits or cutouts, which alter the deformation mode from bending to stretching. This parameter change enables followability while reducing the space required, thus decreasing module height.
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
Improves followability to busbars by absorbing positional tolerances, reducing module height, and minimizing circuit board area while maintaining flexibility in multiple directions.
Implementation Method 1
the stretchable portion has a slit or a cutout formed in a direction intersecting the first direction in a plan view of the circuit body, and the detection line of the stretchable portion is routed along the slit or the cutout
Data Source
AI summary
A busbar module includes: a plurality of busbars arranged along a first direction and connected to battery cells; and a plate-like circuit body having a plurality of detection lines to be connected to the busbars and having flexibility, in which the circuit body includes a main line portion in which the plurality of detection lines is routed and branch portions, branching from the main line portion and in which the detection lines to be connected to the busbars are routed, the branch portions each include a stretchable portion that is stretchable along the first direction, the stretchable portions each have slits or a cutout formed in a direction intersecting the first direction in a plan view of the circuit body, and a detection line of each of the stretchable portions is routed along the slits or the cutout.