Conductor Module Height Reduction via Through-Hole Bus Bar Fixing

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Solution Overview

Problem

Conductor modules used in battery modules face challenges in reducing height while maintaining the durability of mechanical connections between bus bars and film-like wiring members, as stress at these connections can lead to durability issues due to relative movement.

Innovation Solution

A conductor module design featuring a film-like wiring member with through-holes and a reinforcing member that surrounds these holes, along with a fixing member to restrict relative movement, ensuring reliable mechanical connection and reinforcement, thereby eliminating the need for an accommodating member and enhancing durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an accommodating member is used to fix the bus bars and voltage detector, then the durability of mechanical connections is improved, but the height of the conductor module increases

Engineering Contradiction:

Improvedurability of mechanical connection portionVSAvoidheight of conductor module

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The invention transitions from using a separate accommodating member (three-dimensional structure) to forming the fixing structure directly on the wiring member surface (two-dimensional structure). The through-holes and reinforcing members are arranged in specific patterns on the wiring member, eliminating the need for a dedicated accommodating member and reducing overall height while maintaining connection durability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The invention merges the functions of the accommodating member and the wiring member into a single integrated structure. The wiring member itself provides both electrical connection and mechanical fixing functions through its through-holes and reinforcing members, eliminating the need for a separate accommodating member and reducing the conductor module height.

Inventive Principle:

Principle #5Merging (Combining)

2Length of stationary object

If the bus bars are fixed to the film-like wiring member without an accommodating member, then the height of the conductor module is reduced, but the durability of mechanical connections deteriorates due to stress at connection points

Engineering Contradiction:

Improveheight of conductor moduleVSAvoiddurability of mechanical connection portion

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

The invention applies local reinforcement at critical stress points by forming reinforcing members specifically at the through-hole locations where bus bars connect to the wiring member. This localized strengthening addresses the durability issue at connection points without requiring a full accommodating member structure, thus reducing height while improving connection durability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The reinforcing members are formed in advance on the wiring member at the through-hole positions before the bus bars are installed. This preliminary reinforcement prevents stress concentration and potential failure at the connection points, ensuring durability from the outset without needing additional height for an accommodating member.

Inventive Principle:

Principle #10Preliminary action

3Length of stationary object

If through-holes are formed in the wiring member for mechanical connection, then the height is reduced and fixing is improved, but stress concentration may occur at the through-hole locations

Engineering Contradiction:

Improveheight of conductor moduleVSAvoidstrength of wiring member at through-hole locations

Core Design Contradiction:

Length of stationary objectVSStrength

Solution Approach 1:

The reinforcing members are strategically placed at the through-hole locations to provide localized strength enhancement. This targeted reinforcement compensates for the potential stress concentration caused by the through-holes, maintaining the wiring member's overall strength while enabling the height reduction benefits of the through-hole design.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10601017B2Conductor module

Publication Date: 2020.03.24 YAZAKI CORP

AI summary

A conductor module includes a wiring member, a plurality of bus bars, a plurality of locking pieces, and a reinforcing member. A plurality of wirings and through-holes are formed in the wiring member. The bus bar is electrically connected to one of two electrode terminals. The two through-holes are formed in a first opposing region opposing one end face between both end faces of the bus bar opposing each other in a width direction with an electrical connection portion where the bus bar and the wiring are electrically connected interposed therebetween. The locking piece is formed integrally with the bus bar, is arranged in the through-hole, has a distal end positioned radially outward of the through-hole, and fixes the bus bar to the wiring member. The reinforcing member reinforces the wiring member, and is formed to surround the through-hole.