Conductive Module Layout for Via Hole Load Relief

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Solution Overview

Problem

Conventional conductive modules apply circuit conductors that close smoke exhaust ducts, leading to unnecessary forces on via holes due to positional deviation absorption, which is not preferable.

Innovation Solution

A conductive module design with a circuit conductor component featuring two main line portions facing orthogonally, a circuit collection portion with a connector connection, via hole installation, and a positional deviation absorption portion, covered by a circuit cover member with an obtuse angle via hole cover portion to reduce load on via holes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the circuit conductor component closes the smoke exhaust duct, then the circuit conductor component can be integrated into the battery module structure, but unnecessary force acts on the via holes due to flexural deformation of the positional deviation absorption portion

Engineering Contradiction:

Improveintegration of circuit conductor component into battery module structureVSAvoidvia hole durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The circuit conductor component is divided into distinct functional portions: the circuit collection portion with via holes, the positional deviation absorption portion with flexible bend, and the connector connection portion. This segmentation allows each portion to perform its specific function independently, preventing force transmission from the flexible portion to the via holes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The positional deviation absorption portion acts as an intermediary between the rigid circuit collection portion and the flexible connector portion. It absorbs mechanical stress and positional deviations through controlled flexural deformation, preventing unnecessary forces from reaching the via holes while maintaining electrical connectivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the positional deviation absorption portion is made flexible to absorb connector positional deviation, then connector connection reliability is improved, but force associated with flexural deformation is transmitted to the via hole setting portion

Engineering Contradiction:

Improveconnector connection reliabilityVSAvoidvia hole setting portion strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Different portions of the circuit conductor component have different mechanical properties tailored to their functions: the circuit collection portion is rigid to maintain via hole integrity, the positional deviation absorption portion is flexible to absorb connector deviations, and the connector portion is sufficiently flexible for mating. This local differentiation of mechanical properties resolves the contradiction between flexibility and strength requirements.

Inventive Principle:

Principle #3Local quality

3Reliability

If the circuit conductor component extends in the arrangement direction to connect multiple bus bars, then electrical connectivity is improved, but the component becomes more susceptible to positional deviation and mechanical stress

Engineering Contradiction:

Improveelectrical connectivityVSAvoidpositional deviation and mechanical stress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The circuit conductor component incorporates dynamic flexibility through the positional deviation absorption portion, allowing it to adapt to positional deviations and mechanical stresses while maintaining electrical connectivity. The flexible portion can bend and deform elastically to accommodate misalignments without compromising the rigid electrical connections at the via holes.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20250329854A1Conductive module

Publication Date: 2025.10.23 YAZAKI CORP

AI summary

A circuit collection portion includes a connector connection portion, a via hole installation portion, and a positional deviation absorption portion that absorbs positional deviation in an arrangement direction of the connector between the connector connection portion and the via hole installation portion, the circuit cover member includes a cover body that covers the main line portion from a front surface at an assembly completion position, and a via hole cover portion that presses a front surface of the via hole installation portion at the assembly completion position, and intersects the via hole installation portion such that an angle on an inner side of bending with respect to the two main line portions is an obtuse angle, and the via hole cover portion is inclined at the angle with respect to the cover body.