Battery Wiring Module Positioning Protector

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Solution Overview

Problem

The existing battery wiring modules for electric and hybrid cars face challenges in rapid assembly due to manufacturing and assembling errors caused by dimension tolerances, requiring cumbersome alignment and insertion procedures for electrode bolts and busbars.

Innovation Solution

A battery wiring module configuration that includes a protector with positioning sections, which aligns with the single cells before connecting the busbars, allowing for simultaneous positioning and connection, reducing the risk of damage and improving work efficiency by eliminating the need for repeated alignment and contact between busbars and electrode sections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If connecting members are directly inserted into electrode sections, then assembly is simpler, but alignment precision deteriorates due to manufacturing errors and dimension tolerances

Engineering Contradiction:

Improveassembly simplicityVSAvoidalignment precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The positioning section is fitted to the positioned section on the single cell before the connecting members are inserted into the electrode sections. This preliminary positioning action establishes accurate alignment between the battery wiring module and single cells, compensating for manufacturing errors and dimension tolerances that would otherwise require repeated alignment operations during direct insertion assembly

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The battery wiring module is divided into distinct functional sections: the positioning section for alignment, the connecting members for electrical connection, and the protector for structural support. This segmentation allows the positioning function to be performed separately and accurately before the connecting function, resolving the contradiction between assembly simplicity and alignment precision

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If repeated alignment operations are performed for each connecting member, then alignment precision improves, but assembly time increases significantly

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The positioning section is fitted to the positioned section in advance, establishing accurate alignment for all connecting members simultaneously. This preliminary positioning eliminates the need for repeated alignment operations for each connecting member, significantly reducing assembly time while maintaining high alignment precision through the pre-established positioning relationship

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The positioning function is merged into a single integrated positioning section that aligns the entire battery wiring module with the single cells at once. This merging allows all connecting members to be positioned accurately in a single operation rather than requiring separate alignment operations for each member, thereby reducing assembly time while maintaining precision

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If connecting members are brought into contact with electrode sections during positioning, then direct connection is achieved, but risk of damage increases

Engineering Contradiction:

Improveconnection directnessVSAvoiddamage risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The positioning section is fitted to the positioned section before the connecting members contact the electrode sections. This preliminary positioning establishes accurate alignment without requiring the connecting members to be brought into contact with the electrode sections during the positioning operation, thereby eliminating the risk of damage while maintaining direct connection through the subsequent inserting operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The positioning section acts as an intermediary element between the battery wiring module and the single cells during the positioning phase. It enables accurate alignment to be established without direct contact between the connecting members and electrode sections, preventing damage risk while the connecting members are positioned for insertion

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9905832B2Battery wiring module

Publication Date: 2018.02.27 AUTONETWORKS TECH LTD

AI summary

Provided is a battery wiring module to be attached to a single cell group in which a plurality of single cells each having a positive electrode section and a negative electrode section are lined up, and to connect the electrode sections. The battery wiring module includes a connecting member configured to connect the electrode sections, and a protector by which the connecting member is held. The protector has a positioning section that is fitted to positioned sections formed in a single cell prior to the connecting member reaching the electrode sections when the battery wiring module is attached to the single cells. The positioning section is provided projecting farther to the single cell side than the connecting member.