Bus Bar Module With Integrated Insulating Resin Wire Router
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Solution Overview
Problem
Existing bus bar modules in high-voltage detection systems for battery packs face reliability issues in electric connections and poor workability during welding processes, leading to potential deterioration or damage in battery cell voltage uniformity.
Innovation Solution
A bus bar module with integrated insulating resin electric wire routers featuring bus bar reception portions and electric wire routing portions, where each reception portion includes an opening for direct clamping by welding tools and an electric wire tip holding portion to secure the welding area, allowing for stable ultrasonic or resistance welding without the need for additional positioning jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conductor wires are welded to bus bars without integrated positioning structures, then manufacturing complexity is reduced, but welding reliability and workability deteriorate
Solution Approach 1:
The patent integrates the positioning function directly into the bus bar structure by forming positioning protrusions on the bus bar surface and corresponding positioning grooves in the conductor wires. This merging of positioning functionality into the welding components themselves eliminates the need for separate positioning devices or jigs, thereby reducing overall manufacturing complexity while ensuring reliable welding alignment
Solution Approach 2:
The positioning protrusions and grooves act as intermediary structures that mediate between the bus bar and conductor wire. These intermediary features provide precise alignment and stable positioning during the welding process, ensuring that the welding surfaces are properly aligned without requiring additional positioning equipment, thus improving welding reliability while maintaining manufacturing simplicity
2Manufacturing precision
If additional positioning jigs are used for welding conductors to bus bars, then welding precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The bus bar and conductor wire are designed with self-positioning features (protrusions and grooves) that automatically align the components during assembly. This self-service positioning mechanism eliminates the need for external positioning jigs or fixtures, achieving high welding precision through the inherent design of the welding components themselves rather than through additional positioning equipment
Solution Approach 2:
The positioning protrusions and grooves are pre-formed on the bus bar and conductor wire surfaces before the welding process. This preliminary action of creating positioning features in advance ensures that when the components are brought together for welding, they automatically align with the required precision, eliminating the need for last-minute positioning adjustments or external jigs
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
Enhances the reliability of electric connections and simplifies the welding process, reducing manufacturing costs by ensuring secure and efficient bonding between conductors and bus bars, thereby improving the overall structure and performance of the bus bar module.
Implementation Method 1
allowing for stable ultrasonic or resistance welding
Implementation Method 2
allowing for stable ultrasonic or resistance welding
Data Source
AI summary
A bus bar module includes a plurality of bus bars that connects a plurality of unit cells of a battery assembly constituted by the unit cells, a plurality of electric wires that are welded to surfaces of the bus bars, and an electric wire router that is made of insulating resin and includes bus bar reception portions provided side by side in an array direction of the unit cells, wherein each of the bus bar reception portions includes an opening portion that is formed to be opposed to a back surface of a corresponding one of the bus bars in accordance with a connection portion with a conductor of a corresponding one of the electric wires, and an electric wire tip holding portion that holds the vicinity of a welding portion of the conductor.