Conductor Unit Fixing Structure for Battery Modules
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Solution Overview
Problem
Conventional conductive modules in battery systems face challenges in miniaturization due to the arrangement of housing units, fuses, and connection conductors, which lack sufficient rigidity and resistance to vibrations, especially when molded with resin.
Innovation Solution
A fixing structure for a conductor unit that includes a connection conductor connected to battery cell electrodes, a fusible body between the connection conductor and a linear conductor, and an insulative resin-molded member with holding portions inside the resin, which enhances rigidity and vibration resistance by integrating the fusible body and connection conductor within the resin-molded member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a housing unit is provided to arrange connection conductors and fuses, then the components are protected and organized, but the conductive module size increases and miniaturization becomes difficult
Solution Approach 1:
The patent merges the housing unit, connection conductors, and fuses into a single integrated conductor unit. The resin-molded member combines the protective housing function with the mounting structure for connection conductors and fuses, eliminating the need for separate housing units and enabling miniaturization of the battery module.
Solution Approach 2:
The resin-molded member serves multiple functions simultaneously: it acts as a protective housing, provides structural support, mounts connection conductors and fuses, and ensures electrical insulation. This multi-functionality eliminates the need for separate dedicated housing units.
2Volume of moving object
If the fuse and connection conductor are molded with resin to eliminate the casing, then the conductive module is miniaturized, but the rigidity and resistance against vibration decrease
Solution Approach 1:
The patent applies local quality by creating holding portions with specific structural characteristics within the resin-molded member. These holding portions have enhanced rigidity and are strategically positioned to provide localized support at connection points, while the rest of the resin-molded member maintains its lightweight and compact properties.
Solution Approach 2:
The patent uses composite construction by combining resin material with metal connection conductors and fuses within the molded structure. The resin provides insulation and compact integration, while the metal components provide necessary electrical conductivity and structural strength, creating a composite assembly with both lightweight and high-strength characteristics.
3Strength
If multiple holding portions are formed in the connection conductor, then the resin-molded member is securely held and rigidity improves, but the manufacturing complexity increases
Solution Approach 1:
The holding portions are pre-formed as integral parts of the connection conductor before the resin molding process. This preliminary formation of holding portions allows them to be seamlessly integrated into the final molded assembly without requiring additional post-processing steps or separate assembly operations, thereby maintaining ease of manufacture while achieving the desired structural strength.
Data Source
AI summary
A conductor unit includes a connection conductor directly or indirectly connected with at least one electrode terminal in an electrode terminal group of a plurality of battery cells arranged in the same direction, a linear conductor connected with a battery monitoring unit that monitors the battery conditions of the battery cells, a fusible body that is connected between the connection conductor and the linear conductor and fuses when an overcurrent flows between the connection conductor and the linear conductor, and an insulative resin-molded member that contains the fusible body therein. The connection conductor includes holding portions that are disposed inside the resin-molded member, and hold the resin-molded member. The holding portions are formed in at least two places spaced apart from each other.