Battery Wiring Module Cover for Short Circuit Prevention
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Solution Overview
Problem
The existing battery wiring modules are prone to short circuits due to interconnecting portions such as holes or notches in the housing, which can inadvertently connect module-side terminals with bus bars or battery cells, leading to potential electrical shorts.
Innovation Solution
A battery wiring module design that includes a housing with a cover portion having insulating properties to cover the interconnecting portions, a lock portion to restrict the movement of module-side terminals, and a hinge or latch mechanism to ensure the cover portion remains in place, preventing short circuits between module-side terminals and adjacent battery cells or bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an interconnecting portion (hole or notch) is formed in the housing for mold aspects, then the housing can be manufactured using standard injection molding processes, but short circuits can occur inadvertently between module-side terminals and bus bars through the open interconnecting portion
Solution Approach 1:
An insulating cover portion is introduced as an intermediary element between the interconnecting portion (hole/notch) and the external environment. This cover portion has an insulating surface that prevents electrical contact between module-side terminals and bus bars while allowing the interconnecting portion to remain open for manufacturing purposes. The cover acts as a mediator that maintains both the manufacturability of the housing and the electrical insulation reliability.
2Reliability
If the interconnecting portion is covered by an insulating cover, then short circuit prevention is achieved, but the structural complexity of the housing increases
Solution Approach 1:
The insulating cover portion is merged with the housing to form an integrated structure. The cover is configured to be attached to the housing, creating a unified component that combines both the housing function and the insulation function. This merging approach reduces the need for separate insulating components and simplifies the overall structure while maintaining electrical insulation reliability.
Solution Approach 2:
The housing structure is designed to serve multiple functions: it provides mechanical support, enables injection molding manufacturing through interconnecting portions, and ensures electrical insulation through the integrated cover portion. The lock portion also serves dual purposes by both securing the module-side terminal and positioning the interconnecting portion appropriately. This multi-functionality reduces the need for additional components.
3Stability of the object's composition
If the module-side terminal is restricted from moving by a lock portion, then terminal positioning stability is improved, but the interconnecting portion may be formed at a position corresponding to the lock portion creating potential short circuit paths
Solution Approach 1:
The insulating cover portion serves as a mediator that protects the area around the lock portion and interconnecting portion from electrical short circuits. Even when the interconnecting portion is formed at a position corresponding to the lock portion, the cover's insulating surface prevents electrical contact between the module-side terminal and bus bars, maintaining reliability while allowing stable terminal positioning.
Data Source
AI summary
Provided is a battery wiring module that can suppress the occurrence of short circuits. The battery wiring module includes a module-side terminal that is configured to be electrically connected to a bus bar that connects battery terminals of a plurality of battery cells to each other, a wire having one end that is configured to be connected to the module-side terminal, and a housing that is configured to house the wire and the module-side terminal. The housing includes a terminal housing portion that is configured to house the module-side terminal, and a hole portion that is provided on a bottom portion of the terminal housing portion and interconnects an interior region and an exterior region of the terminal housing portion. The battery wiring module further includes a cover portion that has an insulating property and is configured to cover the hole portion.