Connection Module Bus Bar Mounting for Battery Pitch Tolerance
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Solution Overview
Problem
Existing connection modules for power storage modules in vehicles face challenges in maintaining reliable mounting due to variations in electrode pitch and the soft, expandable nature of insulation film sheets, leading to loose connections and reduced reliability under vibration.
Innovation Solution
A connection module with bus bars featuring a flexible insulation first sheet member and hard, non-expandable second sheet members with fixing portions, allowing for independent fixation and expansion to accommodate electrode pitch tolerance, eliminating the need for nut tightening and enhancing mounting reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a sheet member made of expandable synthetic resin is used to hold bus bars, then the sheet member can follow variations in electrode pitch, but the bus bars cannot be controlled in position and may move independently
Solution Approach 1:
The sheet member is divided into multiple sections with different properties: a first sheet member made of expandable synthetic resin for adapting to pitch variations, and second sheet members made of non-expandable synthetic resin for providing stable positioning. This segmentation allows different parts of the system to fulfill different functions simultaneously.
Solution Approach 2:
Different regions of the sheet member structure are assigned different material properties. The first sheet member region is made expandable to follow electrode pitch variations, while the second sheet member regions are made non-expandable to maintain precise bus bar positioning. This local differentiation resolves the contradiction between adaptability and precision.
2Reliability
If the sheet member is tightened with a bolt and nut, then the connection is secured, but the tightening force decreases due to lowering of reaction force after tightening
Solution Approach 1:
A reaction force member is introduced as an intermediary element between the bolt and the sheet member. This reaction force member provides a stable reaction force that prevents the tightening force from decreasing after initial tightening, thereby maintaining connection reliability without requiring excessive initial tightening force.
3Ease of operation
If the sheet member is made soft and expandable for easy mounting, then the mounting operation is easy, but the connection module may not be properly mounted due to inability to control bus bar positions
Solution Approach 1:
The sheet member is segmented into a first sheet member for easy mounting (expandable) and second sheet members for precision positioning (non-expandable). This allows the system to benefit from both ease of operation and manufacturing precision.
Solution Approach 2:
The sheet member structure uses composite material construction with different synthetic resin materials having different expansion properties. This composite approach enables simultaneous achievement of ease of mounting and precise position control.
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
The module effectively follows electrode pitch tolerance and maintains reliable mounting with a simple structure, reducing the likelihood of loosening and deformation, ensuring stable connections even under vibration.
Implementation Method 1
The first sheet member is formed of a flexible insulation member so that the flexible insulation member is expandable at sections between adjacent second sheet members
Implementation Method 2
a first sheet member that is expandable and includes an adhesive member on a surface thereof
Data Source
AI summary
A connection module includes bus bars connecting positive and negative electrode terminals of adjacent power storage elements, a first sheet member that is expandable, and second sheet members fixing each of the bus bars independently. Each of the bus bars includes a fitting portion extending from one edge of the plate member with respect to a width direction (an arrow Y-direction) and fitting in a fixing portion of each second sheet member. The first sheet member holds each second sheet member to which each of the bus bars is fixed, and the first sheet member is expandable at sections between adjacent second sheet members in a longitudinal direction of the first sheet member in a distance of a maximum value of tolerance ΔL max that is a total value of tolerances of an electrode pitch with respect to an arrangement direction in which the adjacent power storage elements are arranged.