Bus Bar Module Terminal Projection for Space Optimization

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Solution Overview

Problem

Conventional battery wiring modules narrow the space perpendicular to the arranging direction of batteries due to extended barrel portion housings, limiting the arrangement of components like radiator tubes and requiring larger module sizes.

Innovation Solution

A bus bar module with terminals featuring an insertion hole and a projecting section that extends along the battery arranging direction, allowing for wider space utilization perpendicular to the battery arrangement, and a case design with housing portions that accommodate these terminals to prevent short-circuiting and enhance space efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If the barrel portion housing is extended forward of the bus bar housing to reduce the pitch between single batteries, then the arranging direction size is reduced, but the space perpendicular to the arranging direction is narrowed

Engineering Contradiction:

Improvepitch between single batteriesVSAvoidspace perpendicular to arranging direction

Core Design Contradiction:

Length of moving objectVSArea of stationary object

Solution Approach 1:

The projecting section is oriented perpendicular to the arranging direction of batteries, utilizing the width dimension instead of the length dimension. This dimensional shift allows the terminal to extend in the direction crossing the battery arrangement, thereby reducing the pitch between batteries without compromising the perpendicular space required for other components.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The terminal structure employs asymmetric design where the projecting section extends only in the width direction (perpendicular to battery arrangement) rather than symmetrically in all directions. This asymmetric configuration optimizes space utilization by directing the projection only where it serves the electrical connection function, avoiding interference with components in the perpendicular space.

Inventive Principle:

Principle #4Asymmetry

2Volume of moving object

If the barrel portion housing is extended forward to downsize the arranging direction, then compactness in arranging direction is improved, but component arrangement flexibility is reduced

Engineering Contradiction:

Improvemodule size in arranging directionVSAvoidcomponent arrangement flexibility

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

By shifting the projection direction to the width dimension (perpendicular to battery arrangement), the invention preserves the longitudinal space for component arrangement flexibility while achieving compactness in the arranging direction through optimized terminal configuration.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Area of stationary object

If the projecting section extends perpendicular to the battery arranging direction, then space utilization in that direction is improved, but terminal isolation becomes more difficult

Engineering Contradiction:

Improvespace perpendicular to battery arrangementVSAvoidterminal isolation

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The case structure implements localized housing sections that specifically accommodate each terminal's projecting section. This localized quality ensures that each terminal is isolated within its own housing portion, preventing short-circuits while maintaining the perpendicular space extension for improved component arrangement.

Inventive Principle:

Principle #3Local quality

4Ease of operation

If the terminal main body is extended to provide insertion hole, then battery connection function is improved, but overall terminal size increases

Engineering Contradiction:

Improvebattery connection functionVSAvoidterminal size

Core Design Contradiction:

Ease of operationVSLength of stationary object

Solution Approach 1:

The terminal extends its functionality in the width dimension (perpendicular to battery arrangement) rather than increasing length in the battery arranging direction. This dimensional shift provides the necessary insertion hole and connection function while maintaining compactness in the critical arranging direction.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS9887408B2Bus bar module and power unit

Publication Date: 2018.02.06 YAZAKI CORP

AI summary

The bus bar module includes: bus bars for connecting the batteries in series by connecting the positive electrode and the negative electrode of the adjacent batteries; a plurality of terminals electrically connected to the electrodes of the batteries; and a case for housing the bus bars and the terminals. Each terminal includes: a terminal main body on which an insertion hole is provided for inserting the electrode of the battery; and a projecting section projecting from a part of a peripheral edge of the terminal main body in a surface extending direction of the terminal main body. The terminal is arranged so that a projecting direction of the projecting section is along an arranging direction of the batteries.