Busbar Wiring Module Clearance Structure for Protector Deformation
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Solution Overview
Problem
The existing wiring modules for power storage elements are prone to deformation due to misalignment of busbars with insulation protectors, causing bolts and nuts to apply excessive force on the protectors during assembly.
Innovation Solution
A wiring module design featuring an insulation protector made of synthetic resin with specific clearances to accommodate the nut or head portion of the bolt, reducing the likelihood of contact and deformation, and including a busbar with an electrode connection and insertion base portion to securely position and connect electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the busbar position is deviated from the correct position, then the assembly process becomes simpler, but the bolt or nut contacts the insulation protector causing deformation
Solution Approach 1:
The receiving portion is designed with an inner shape larger than the nut or head portion, creating clearance space beforehand. This cushioning space prevents contact between the fastening components and the insulation protector, accommodating potential position deviations without causing deformation or damage to the insulation protector.
Solution Approach 2:
The receiving portion's dimensions are specifically designed with clearance parameters - the inner shape is made larger than the outer shape of the nut or head portion. This parameter change creates a tolerance zone that absorbs positioning errors while maintaining proper fastening function and preventing damage to the insulation protector.
2Strength
If a large force is applied to the bolt and nut during screwing, then the fastening is more secure, but the insulation protector deforms
Solution Approach 1:
The receiving portion provides a cushioning space between the fastening components (nut or head portion) and the insulation protector. This allows large tightening forces to be applied to achieve secure fastening while the cushioning space prevents these forces from being transmitted to the insulation protector, avoiding deformation.
3Reliability
If the receiving portion is made larger to accommodate the nut or head portion, then contact with the insulation protector is reduced, but the device complexity increases
Solution Approach 1:
The receiving portion is integrated into the insulation protector as a unified structure rather than a separate component. This merging approach provides the necessary clearance space to prevent contact between fastening components and the insulation protector body, while avoiding the complexity of additional separate parts or complex assembly procedures.
Data Source
AI summary
A wiring module to be attached to multiple power storage elements including electrodes includes an insulation protector made of synthetic resin having insulating properties, a busbar held by the insulation protector and connected to the electrode, a bolt including a shaft portion that extends through the busbar and a head portion that is at an end of the shaft portion, and a nut that is screwed onto the shaft portion of the bolt. The busbar includes an electrode connection portion that is connected to the electrode and extends in an extending direction and an insertion base portion that extends in a first direction crossing the extending direction and through which the shaft portion of the bolt extends. The insulation protector includes a holding portion that holds and positions the electrode connection portion and a receiving portion receiving the nut or the head portion therein.