Battery Wiring Module Layout Without Injection-Molded Protectors

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing manufacturing process for battery modules requires a mold for injection-molding the resin protector, leading to increased manufacturing costs for the wiring module.

Innovation Solution

A wiring module is designed with an insulative sheet and electric wires disposed along the arrangement direction, which are electrically connected to bus bars attached to the power storage elements, eliminating the need for injection-molding and thus reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mold for injection-molding the resin protector is used, then the wiring module can be manufactured with protected bus bars, but the manufacturing cost increases

Engineering Contradiction:

Improveprotection of bus barsVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the expensive injection-molded resin protector with a simple insulative sheet material that can be easily manufactured and disposed of or replaced. This insulative sheet serves the same protective function for the bus bars without requiring costly mold investment for injection molding, thereby reducing manufacturing costs while maintaining reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If a mold for injection-molding the resin protector is used, then the wiring module can be manufactured with protected bus bars, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveprotection of bus barsVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the essential protective function from the complex injection-molding process and implements it through a simple insulative sheet. By separating the protective function from the complex manufacturing process, the solution maintains bus bar protection while eliminating the need for expensive molds and complex injection-molding equipment, thereby simplifying the overall manufacturing process.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If electric wires are disposed on the surface of the insulative sheet, then the manufacturing cost is reduced, but the position accuracy must be maintained

Engineering Contradiction:

Improvemanufacturing costVSAvoidposition accuracy of electric wires

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-arranging the electric wires on the insulative sheet before final assembly. The wires are positioned and fixed on the sheet surface in advance, ensuring correct positioning without requiring complex positioning mechanisms during assembly. This preliminary arrangement maintains manufacturing precision while keeping the process simple and cost-effective.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12334580B2Wiring module, power storage module, bus bar, and manufacturing method for power storage module

Publication Date: 2025.06.17 AUTONETWORKS TECH LTD

AI summary

A wiring module to be attached to a plurality of power storage elements each having an electrode terminal and arranged in an arrangement direction, the wiring module including: an insulative sheet; and a plurality of electric wires disposed along the arrangement direction, on a surface of the sheet. The electric wires are respectively electrically connected to bus bars that are connected to electrode terminals of the plurality of power storage elements.