Battery Wiring Module With Hinged Terminals for Lead Misalignment
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Solution Overview
Problem
The manufacturing tolerances in the connection of electrode leads of battery cells in high-pressure battery packs lead to potential electrical connection errors due to bending and welding, resulting in ineffective contact between electrode leads and module terminals.
Innovation Solution
A wiring module is designed to be coupled to a battery stack member with electrode leads, featuring terminals connected via a hinge portion that allows for movable terminal housing portions, enabling the electrode connection portions to align correctly with the electrode leads, reducing the likelihood of electrical connection errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrode leads are bent and overlapped to connect adjacent battery cells, then busbars are eliminated and electrical connection is achieved, but manufacturing tolerances cause ineffective contact between electrode leads and module terminals
Solution Approach 1:
The terminal housing portion is made movable relative to the protector body through a hinge portion, allowing the terminal to dynamically adjust its position to accommodate manufacturing tolerances of the electrode leads. This dynamic adjustment ensures reliable electrical connection despite variations in lead position after bending and welding.
Solution Approach 2:
The terminal housing portion acts as an intermediary element between the fixed protector body and the electrode lead. It provides a flexible interface that can absorb position deviations through its movable connection, ensuring that the electrode connection portion maintains effective contact with the electrode lead.
2Ease of operation
If electrode leads are bent to be closer to each other for overlapping connection, then electrical connection between adjacent cells is achieved, but manufacturing tolerances in the front-rear direction cause contact failure
Solution Approach 1:
The movable terminal housing portion compensates for front-rear direction position deviations of the electrode leads. By allowing the terminal to move relative to the protector body, it accommodates manufacturing tolerances without requiring extremely precise assembly, thus maintaining ease of operation while ensuring connection reliability.
3Stability of the object's composition
If fixed terminal housing portions are used, then structural stability is maintained, but electrical connection errors occur due to manufacturing tolerances
Solution Approach 1:
The terminal housing portion is segmented from the protector body through the hinge portion, creating a movable joint. This segmentation allows the terminal housing portion to independently adjust its position to accommodate electrode lead variations while the protector body maintains its overall structural stability.
Solution Approach 2:
The hinge portion introduces dynamic capability to the otherwise static terminal housing structure. This allows the system to maintain structural stability at the protector level while enabling positional adjustment at the terminal level to ensure reliable electrical connection despite manufacturing tolerances.
Data Source
AI summary
A wiring module is to be coupled to a battery stack member that includes laminated type batteries having electrode leads being stacked and the electrode leads of the laminated type batteries are overlapped and connected and configured as connection portions. The wiring module is to be coupled to the battery stack member including the connection portions in a coupling direction that is perpendicular to a plate thickness direction of the connection portions. The wiring module includes terminals, electric wires connected to the terminals, and a protector holding the terminals and the electric wires. The electrode leads include connection electrode leads that are configured as the connection portions. The terminals include electrode connection portions that are electrically connected to the connection electrode leads. The protector includes a protector body and terminal housing portions in which the terminals are disposed with being positioned.