Transformable Battery Conductive Module for Compact Terminal Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conductive modules for vehicles with battery modules have a large occupation area due to flexible wiring components, which increases with the capacity of battery cells, leading to inefficiencies in space usage and potential interference with other components.
Innovation Solution
A miniaturized conductive module design featuring interterminal connection components with flexible wiring components that transform between temporary and formal mounted forms, allowing for efficient connection and reduced footprint by bending transformation, utilizing flexible printed circuit boards with voltage detection lines and insulating members to cover terminal groups, thereby minimizing space occupation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flexible wiring component covers the area between the electrode terminal groups on the battery module, then the electrical connection and voltage detection functions are ensured, but the occupation area on the battery module becomes large
Solution Approach 1:
The flexible wiring component is designed to transform between a temporary mounted form during assembly and a formal mounted form after assembly. This dynamic transformation allows the wiring component to occupy less space in the final configuration while ensuring proper electrical connections are made during the assembly process
Solution Approach 2:
The flexible wiring component utilizes three-dimensional space by folding and transforming between different configurations. The component can be temporarily extended in one dimension during assembly to reach connection points, then transformed to a compact form that minimizes occupation area in the final assembled state
2Quantity of substance
If the interval between the electrode terminal groups is increased due to increase in capacity of the battery cells, then the battery cell capacity is improved, but the useless area in the insulating member increases
Solution Approach 1:
The flexible wiring component with transforming portions can dynamically adjust its configuration to match the increased interval between terminal groups. The transforming portions allow the wiring to extend further when needed while maintaining a compact form factor, reducing the useless area in the insulating member even when terminal groups are spaced farther apart
Solution Approach 2:
The flexible wiring component changes its physical parameters (shape, configuration, effective length) through transformation between temporary and formal mounted forms. This parameter change allows the same component to effectively cover larger intervals between terminal groups without proportionally increasing the insulating member area
Data Source
AI summary
The conductive module includes interterminal connection component groups for respective electrode terminal groups, and flexible wiring components for the respective interterminal connection component groups. Each of the flexible wiring components includes a transforming portion performing transformation into a temporary mounted form at the time when each of interterminal connection components is connected with electrode terminals and a formal mounted form after work of the connection. Each of the transforming portions is provided in part of the crossing portion on a subsidiary conductive portion side and/or in the subsidiary conductive portion, and displaces a portion between a main conductive portion side and the subsidiary conductive portion side between the temporary mounted form and the formal mounted form by the transformation.