Wound Insulated Connection Wire for Flexible Battery Pack Routing
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Solution Overview
Problem
Existing high-voltage connection wires and busbars face challenges in flexibility, making it difficult to arrange them in the limited space within battery packs, particularly in applications requiring high current connections for portable devices and electric vehicles.
Innovation Solution
A connection wire with a wound insulating member and conductive members, allowing for increased flexibility by forming a bent portion with a reduced radius of curvature, and optionally including a shielding circuit and short circuit prevention sheet for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the cross-sectional area of HV wire and HV busbar is increased to handle high current, then the current carrying capacity is improved, but the flexibility and ease of arrangement in limited space deteriorates
Solution Approach 1:
The connection wire is divided into multiple strands rather than using a single solid conductor. This segmentation allows the wire to maintain high current carrying capacity through increased total cross-sectional area while simultaneously improving flexibility, as multiple thinner strands can bend more easily than a single thick conductor.
Solution Approach 2:
The connection wire is covered with an insulating sheath that provides electrical insulation while allowing the underlying stranded conductor to maintain its flexibility. The sheath protects the multiple strands while not significantly impeding their ability to bend and conform to limited spaces within the battery pack.
2Ease of operation
If flexible HV wires are used to improve arrangement in limited space, then the ease of operation is improved, but the reliability and connection stability deteriorates
Solution Approach 1:
The connection wire combines multiple materials with complementary properties: conductive metal strands for electrical conductivity, insulating material for electrical isolation, and potentially reinforcing elements for mechanical strength. This composite structure maintains reliability while enabling flexibility for spatial arrangement.
Solution Approach 2:
The wire construction parameters are optimized by controlling the strand diameter, number of strands, and insulation thickness to achieve the right balance between flexibility and mechanical strength. The insulation layer parameters are specifically designed to provide adequate electrical isolation while maintaining overall wire flexibility.
3Reliability
If the insulating member is made thicker to prevent short circuits, then the reliability is improved, but the flexibility and ease of arrangement deteriorates
Solution Approach 1:
The insulating member may have varying thickness at different locations along the connection wire, with thicker insulation at critical areas where short circuit risk is higher (such as near connection terminals) and thinner insulation in areas where flexibility is more important. This localized approach maintains reliability where needed while preserving overall flexibility.
Data Source
AI summary
A connection wire according to one embodiment of the present disclosure includes a plurality of conductive members; and an insulating member surrounding the conductive members, wherein the insulating member has a wound shape, and is located on an inner surface of the insulating member on which the conductive members are wound.