Battery Wiring Module Segmentation and Planar Design
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Solution Overview
Problem
Existing battery wiring modules for in-vehicle battery packs face challenges in durability due to non-uniform voltage across battery cells, leading to potential voltage drop and increased manufacturing costs, with limited versatility and complex wiring structures.
Innovation Solution
A battery wiring module design featuring parallel linear conductors with busbars and insulating resin coatings, allowing for simple and efficient electrical connections between battery cells, reducing the need for dedicated insulation frames and enhancing connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple voltage detection lines are bound together in a busbar module, then voltage detection functionality is achieved, but the wiring becomes thick and difficult to bend
Solution Approach 1:
The patent divides the bound voltage detection lines into separate individual lines, allowing each line to remain thin and flexible while still achieving voltage detection functionality across multiple battery cells. This segmentation eliminates the thickness and rigidity issues caused by binding multiple lines together.
Solution Approach 2:
The patent transitions from a three-dimensional bound structure (multiple lines tied together) to a two-dimensional planar arrangement where voltage detection lines are laid out separately on the battery module surface, connected through connection members. This dimensional change maintains detection capability while improving flexibility and reducing thickness.
2Reliability
If round terminals are crimped to voltage detection lines and fixed with nuts, then electrical connection is achieved, but contact resistance increases causing voltage drop
Solution Approach 1:
The patent extracts and eliminates the round terminal and nut components from the connection structure. Instead of using crimped round terminals with nuts, the invention directly connects voltage detection lines to connection members through welding or conductive adhesive, removing the intermediate components that cause contact resistance and voltage drop.
Solution Approach 2:
The patent replaces the mechanical connection method (crimping and nut fastening) with a direct electrical connection method such as welding or conductive adhesive bonding. This substitution eliminates the mechanical contact interface that generates resistance, achieving lower contact resistance and reduced voltage drop.
3Reliability
If dedicated insulation frames with protrusion portions are used for each battery cell type, then insulation and structural support are achieved, but manufacturing cost increases and versatility decreases
Solution Approach 1:
The patent creates a universal battery wiring module design where connection members and insulating structures can be used across different battery cell types and configurations. The module architecture allows the same basic components to serve multiple functions and adapt to various battery pack designs, eliminating the need for dedicated insulation frames for each cell type.
Solution Approach 2:
The patent merges the insulation frame function with the connection member structure, integrating support and insulation capabilities into a unified component system. This consolidation reduces the number of separate parts needed and simplifies the overall structure, improving manufacturing efficiency and versatility.
Data Source
AI summary
Provided is a battery wiring module including: a plurality of linear conductors disposed in parallel with a predetermined gap therebetween; a plurality of busbars disposed in parallel along at least one of the linear conductors disposed at both ends having a predetermined gap therebetween so as to electrically connect electrode terminals provided in at least two battery cells connected to each other in the same direction among the plurality of battery cells overlapping each other in the same direction, the electrode terminals being arranged in the same direction; a first insulating resin portion which integrally coats the outer peripheral portions of the plurality of linear conductors and a side edge portion adjacent to the linear conductor in the plurality of busbars; and a connection conductor which electrically connects the linear conductor and the busbar to each other.