Battery Wiring Module Insulation via Elastic Cover
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Solution Overview
Problem
Battery wiring modules for electric and hybrid cars face issues with short circuits due to exposed connecting members coming into contact with conductive materials around the battery, as existing designs feature slits that can lead to exposure and increased risk of short circuits.
Innovation Solution
A battery wiring module with a resin protector that includes holding portions with a surrounding wall and a coming-off preventing projection with an elastic piece, which covers the beveled corner of the connecting member, preventing it from being exposed and thus reducing the risk of short circuits without the need for special machining or cut-out portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If slits are formed in the holding portion to provide a coming-off preventing projection, then the connecting member can be prevented from coming off, but the connecting member becomes exposed at the slit portion creating short circuit risk
Solution Approach 1:
The coming-off preventing projection is nested within the holding portion structure, with the elastic piece integrated into the resin body. The projection is formed as an internal feature rather than an external protrusion, allowing the connecting member to be retained without exposure to the external environment.
Solution Approach 2:
The elastic piece acts as a flexible component within the resin holding portion, allowing it to deform and engage with the connecting member to prevent coming off, while the surrounding resin structure maintains the insulation and prevents exposure.
2Reliability
If cut-out portions are formed in the holding portion to provide locking projections, then the connecting member can be locked, but the structure becomes complex and requires special machining
Solution Approach 1:
The holding portion is segmented into distinct functional regions: the elastic piece for engagement, the coming-off preventing projection for retention, and the surrounding wall for insulation and structural support. This segmentation allows each feature to perform its specific function without requiring complex overall structure.
Solution Approach 2:
The elastic piece changes its physical state from a relaxed position to a deformed position during engagement with the connecting member. This parameter change (elastic deformation) provides the locking action without requiring permanent structural modifications or complex machining.
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
The solution effectively prevents short circuits by ensuring the connecting members are not exposed, maintaining insulation, and allowing for reliable connection without the need for additional machining or space, while also enabling the integration of voltage detecting terminals for dual functionality.
Implementation Method 1
a coming-off preventing projection provided with an elastic piece capable of being bent and deformed that is disposed so as to cover the beveled corner of the corresponding connecting member
Data Source
AI summary
A battery wiring module may include a connecting member and a resin protector. The connecting member may be connected to an electrode terminal, and the connecting member may include a beveled corner. The resin protector may be made of insulating resin and include a holding portion and a coming-off preventing projection. The holding portion may hold the connecting member and may be provided with a surrounding wall that surrounds a peripheral edge of the connecting member. The coming-off preventing projection may include an elastic piece disposed cover the beveled corner of the connecting member and thereby limit movement of the connecting member.