Bus Bar Module Thermistor Routing to Reduce Height and Vent Blockage
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Solution Overview
Problem
The existing bus bar module design is bulky due to the routing of temperature detection wires, which increases the size and height of the case and can hinder gas release from the smoke exhaust portion between the electrodes of the single cell.
Innovation Solution
The thermistor attachment portion is integrated into the electric wire routing groove portion, allowing the temperature measurement wire to be routed perpendicular to the attaching direction and coinciding with the voltage detection wires, reducing the overall size and height of the bus bar module while preventing protrusion above the smoke exhaust portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the detection wire is bent and routed to a side, then the thermistor can be accommodated, but the module becomes bulky upward
Solution Approach 1:
The patent combines the thermistor attachment portion with the electric wire routing groove portion into a single integrated structure. The thermistor is mounted on the side wall of the routing groove, allowing the detection wire to extend downward along the groove rather than bending upward. This merging eliminates the need for separate accommodation spaces and reduces overall module height.
Solution Approach 2:
Instead of routing the detection wire upward and bending it sideways (using vertical space), the patent redirects the wire to extend downward along the side wall of the routing groove (using horizontal/longitudinal space). This dimensional change in wire routing path allows the module to maintain a compact height while still accommodating both the thermistor and wire routing functions.
2Reliability
If a separate accommodating portion for the thermistor is provided, then the thermistor can be properly accommodated, but the case size increases
Solution Approach 1:
The patent integrates the thermistor attachment portion directly into the side wall of the electric wire routing groove portion. This merging of functions means the same structural element (the routing groove) serves dual purposes: routing electric wires and accommodating the thermistor. Consequently, no additional case area is required beyond what is already needed for wire routing.
Solution Approach 2:
The electric wire routing groove portion is designed to serve multiple functions: it routes the voltage detection electric wires and simultaneously provides an attachment surface for the thermistor. This multi-functionality eliminates the need for dedicated separate spaces for each component, thereby reducing the overall case area while maintaining all necessary functionalities.
3Reliability
If the accommodating portion or routing groove protrudes above the smoke exhaust portion, then the thermistor can be accommodated, but gas release is hindered
Solution Approach 1:
The patent positions the thermistor attachment portion at a specific location on the side wall of the routing groove that is lower than the smoke exhaust portion. This localized placement ensures that the thermistor and its detection wire do not protrude into the smoke exhaust path. The side wall mounting provides adequate clearance, allowing gas to flow freely through the smoke exhaust portion without obstruction while still maintaining proper thermistor accommodation and temperature measurement capability.
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
This configuration reduces the size and height of the bus bar module, preventing interference with the smoke exhaust and enhancing gas release, while maintaining effective temperature measurement.
Implementation Method 1
a temperature measurement electric wire connected to a thermistor configured to measure a temperature of at least one of the plurality of single cells
Data Source
AI summary
A bus bar module includes: a case attached to a battery assembly including a plurality of single cells; a bus bar supported by the case and electrically connected to electrodes of the plurality of single cells of the battery assembly; and a plurality of electric wires routed in the case. The plurality of electric wires include: a plurality of voltage detection electric wires connected to the bus bar, and a temperature measurement electric wire connected to a thermistor configured to measure a temperature of at least one of the plurality of single cells. The case includes: an electric wire routing groove portion in which the plurality of voltage detection electric wires are routed, and a thermistor attachment portion to which the thermistor is attached. The thermistor attachment portion is provided in the electric wire routing groove portion.