Aluminum Wiring Module for Battery Cell Groups
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Solution Overview
Problem
Conventional wiring modules for battery systems, which use copper or copper alloys for busbars and voltage detection terminals, result in increased weight and potential galvanic corrosion issues.
Innovation Solution
A wiring module utilizing aluminum or aluminum alloy connection members and coated aluminum or aluminum alloy voltage detection wires, eliminating the need for voltage detection terminals and reducing weight by integrating the connection member with the voltage detection wire, and incorporating crimping and upwardly extending portions for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper or copper alloy busbars and voltage detection terminals are used, then electrical conductivity and connection reliability are improved, but the overall weight of the wiring module increases
Solution Approach 1:
The patent changes the material parameter from copper to aluminum, substituting a lighter material that maintains adequate electrical conductivity for the wiring module application, thereby reducing overall weight while preserving connection reliability
Solution Approach 2:
The patent merges the voltage detection terminal and the busbar into a single integrated aluminum component, eliminating the need for separate copper terminals and reducing the total number of parts and materials, which contributes to weight reduction while maintaining functional reliability
2Reliability
If copper or copper alloy busbars and voltage detection terminals are used, then electrical connection performance is improved, but galvanic corrosion occurs due to material dissimilarity
Solution Approach 1:
The patent applies homogeneity by using aluminum material consistently for both the busbar and voltage detection terminal, eliminating material dissimilarity between connected components. This prevents galvanic corrosion by ensuring both parts are made of the same metal, thereby removing the electrochemical potential difference that causes corrosion in dissimilar metal connections
3Reliability
If separate voltage detection terminals are used, then voltage detection function is ensured, but device complexity and number of parts increase
Solution Approach 1:
The patent combines the voltage detection terminal function with the busbar structure by integrating both into a single aluminum component. The busbar serves dual purposes: electrical connection and voltage detection, thereby reducing the number of separate parts while ensuring the voltage detection function remains intact
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 solution provides a lightweight wiring module with reduced galvanic corrosion risk and improved connection reliability, maintaining the connection state between the voltage detection wire and connection member.
Implementation Method 1
an exposed core wire that is exposed at an end portion of the voltage detection wire is connected to the connection member by welding
Implementation Method 2
a voltage detection wire formed by coating a core wire metallic, for example, aluminum or an aluminum alloy, with an insulation coating
Implementation Method 3
since the connection member and the core wire of the voltage detection wire are composed of the same metal material, the occurrence of galvanic corrosion due to, for example, intrusion of water containing salt can also be prevented
Data Source
AI summary
A wiring module to be attached to a battery module including a single cell group in which a plurality of single cells having positive and negative electrode terminals are lined up includes a connection member that is made of aluminum or an aluminum alloy and that electrically connects adjacent electrode terminals to each other and a voltage detection wire formed by coating a core wire made of aluminum or aluminum alloy with an insulation coating. An exposed core wire that is exposed at an end portion of the voltage detection wire is connected to the connection member by welding.