Battery Module Wire-Fixing Ribs for Sensing Wire Management
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Solution Overview
Problem
Conventional battery modules using adhesives or adhesive tapes to fix voltage sensing wires suffer from aesthetic deterioration, increased manufacturing costs, and non-uniformity, leading to potential wire separation during production.
Innovation Solution
The battery module incorporates wire-fixing ribs on the module covers to securely fasten voltage sensing wires without adhesives, ensuring an aesthetically pleasing appearance, reducing costs, and simplifying the manufacturing process by pushing the wires into place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If adhesive or adhesive tape is used to fix voltage sensing wires, then the wires can be fixed to the battery module, but the aesthetic appearance of the battery module is greatly deteriorated
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical fixing mechanism (ribs). The ribs are formed on the module cover and mechanically engage with the wires through friction and physical constraint, eliminating the need for adhesive while maintaining secure wire fixation and preserving aesthetic appearance.
Solution Approach 2:
The patent extracts and removes the adhesive material from the wire fixing system. By eliminating the adhesive component entirely and replacing it with integrated ribs on the module cover, the solution removes the source of aesthetic deterioration while maintaining wire fixation functionality.
2Reliability
If adhesive is used to fix the wires, then the wires can be secured, but material cost and manufacturing cost are increased
Solution Approach 1:
The patent merges the wire fixing function into the module cover structure itself by forming ribs as an integral part of the cover. This eliminates the need for separate adhesive materials and reduces the number of components and assembly steps, thereby reducing material cost and manufacturing cost while maintaining reliable wire fixation.
Solution Approach 2:
The module cover with integrated ribs provides self-service wire fixation without requiring external adhesive materials. The ribs are formed during mold injection of the module cover, making the fixing structure self-contained and eliminating additional material costs and manufacturing complexity.
3Reliability
If adhesive is used to fix the wires, then the wires can be attached, but the manufacturing process becomes irregular and tact time is increased
Solution Approach 1:
The ribs are pre-formed on the module cover during the mold injection process before wire installation. This preliminary formation of the fixing structure eliminates the need for separate adhesive application steps, ensures uniform wire positioning from the start, and streamlines the manufacturing process for improved productivity and reduced tact time.
Solution Approach 2:
The patent replaces the complex, multi-step adhesive application and curing process with a simple mechanical insertion process. Wires are directly inserted into the rib structures and secured through friction and physical constraint, eliminating irregularities in adhesive application and significantly reducing manufacturing time and improving productivity.
Data Source
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AI summary
A battery module including wire-fixing ribs is disclosed. The battery module includes a battery cell stack constituted by a plurality of battery cells, the battery cell stack being configured such that the battery cells are stacked in the state in which the battery cells are adjacent to each other laterally, the battery cell stack being provided in one end thereof with a step part, a first module cover and a second module cover coupled to each other while covering electrode terminals provided on opposite sides of the battery cell stack, terminal plates for electrically connecting electrode terminals of the battery cells to each other, a battery management system (BMS) mounted in the step part of the battery cell stack for controlling the operation of the battery module, and voltage sensing wires arranged on the battery cell stack, each of the voltage sensing wires having one end connected to a corresponding one of voltage sensing terminals formed on portions of the terminal plates and the other end connected to the BMS.