Battery Wiring Module with Integrated Bus Bar Insulation
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Solution Overview
Problem
Existing battery wiring modules for in-vehicle battery packs face challenges with complex configurations, high manufacturing costs, and reduced versatility due to the need for dedicated insulation frame components for each battery pack size, as well as issues with wire thickness, weight, and resistance at connection points.
Innovation Solution
A battery wiring module with linear conductors and bus bars arranged in parallel, integrated with an insulation resin part that covers the bus bars' side edges and through holes, allowing for hot pressing to form a pillar-like connection that eliminates the need for dedicated insulation frames and simplifies assembly, while maintaining electrical connectivity and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple voltage detection wires are added to monitor battery cell voltages, then battery safety and monitoring capability are improved, but the overall wire thickness increases making bending difficult and the weight increases making wiring work difficult
Solution Approach 1:
The patent combines multiple voltage detection wires into a single flat cable structure where multiple conductive wires are integrated together. This merging approach maintains the monitoring capability for multiple battery cells while reducing overall thickness and weight compared to using separate round terminals for each wire, thereby improving wiring workability.
Solution Approach 2:
The patent uses a flat cable with a flexible insulation structure that allows the bundled voltage detection wires to be easily bent and routed. The flat cable design with integrated insulation enables the wires to maintain flexibility despite having multiple conductors, solving the bending difficulty issue.
2Reliability
If round terminals are crimped to voltage detection wires and fastened to electrode terminals with nuts, then electrical connection is established, but the contact face resistance between bus bar and round terminal becomes large causing voltage drop
Solution Approach 1:
The patent replaces the mechanical crimping and nut fastening system with a welding system. The flat cable conductors are directly welded to the bus bars, eliminating the intermediate round terminals and their associated contact resistance. This substitution of mechanical connection with welding reduces contact face resistance and prevents voltage drop while maintaining reliable electrical connection.
3Strength
If dedicated insulation frame components are used for each battery pack size, then structural integrity is maintained, but manufacturing cost increases and versatility decreases
Solution Approach 1:
The patent uses a universal bus bar module design that can accommodate different battery pack sizes through standardized interfaces and configurable arrangements. The same basic module structure can be adapted to various battery cell configurations (e.g., different numbers of cells in series/parallel), eliminating the need for dedicated insulation frames for each size and reducing manufacturing costs while maintaining structural integrity.
Solution Approach 2:
The patent divides the battery wiring system into modular bus bar segments that can be independently configured and assembled. This segmentation allows the same basic module components to be arranged in different configurations to match various battery pack sizes, providing versatility without requiring completely different dedicated frames for each application.
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
This configuration simplifies wiring, improves versatility by accommodating various battery pack sizes, reduces manufacturing costs, and minimizes voltage drop by optimizing the connection method between bus bars and linear conductors.
Implementation Method 1
a bus bar connection part, subjected to a hot press so as to cover a part of each of the through holes
Data Source
AI summary
A battery wiring module is to be combined with a battery module including a plurality of battery cells stacked in a state of being alternatively reversed so that a positive electrode terminal and a negative electrode terminal are adjoined between the adjacent battery cells. The battery wiring module is provided with a plurality of linear conductors which are arranged at an interval, a plurality of bus bars which are arranged at an interval along to at least one side of the plurality of linear conductors so that each of the plurality of bus bars electrically connects the positive electrode terminal and the negative electrode terminal adjacent to each other, andan insulation resin part including both a covering part for covering an outer periphery of the plurality of linear conductors and a bus bar connection part.