Flexible Conductive Module for Connector Orientation Changes
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Solution Overview
Problem
Conductive modules are unable to adapt to changes in the insertion/removal direction of connectors, which limits their flexibility in accommodating different installation locations of battery monitoring units.
Innovation Solution
A flexible and flat wiring component with a wiring main body, intersection body, and branch bodies, along with a bent region, allows the connector to change its insertion/removal direction, enabling it to be positioned appropriately relative to the mating connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connector position is fixed according to a specific insertion/removal direction, then the manufacturing and assembly process is simplified, but the conductive module cannot adapt to changes in mating connector arrangement at different installation locations
Solution Approach 1:
The wiring component is designed with a bent region that enables dynamic reconfiguration. By bending the bent region, the insertion/removal direction of the connector can be changed between first and second directions, allowing the conductive module to adapt to different mating connector arrangements without requiring multiple fixed wiring configurations
Solution Approach 2:
The wiring component is constructed as a flexible and flat structure that can be bent at the bent region. This flexibility allows the wiring component to change its orientation and accommodate different insertion/removal directions while maintaining electrical connectivity, resolving the contradiction between adaptability and structural complexity
2Adaptability or versatility
If the wiring component is designed with multiple routing paths for different directions, then adaptability to different installation locations is improved, but the wiring component complexity and production difficulty increase
Solution Approach 1:
The wiring component is segmented into distinct functional regions: a wiring main body, a bent region, and a connector. This segmentation allows each part to be optimized independently - the wiring main body maintains standard routing for ease of manufacture, while the bent region provides the necessary flexibility for adaptability without complicating the overall manufacturing process
3Adaptability or versatility
If the connector can change insertion/removal direction through a flexible wiring component, then adaptability to different mating connector arrangements is achieved, but the risk of wiring damage during bending increases
Solution Approach 1:
The bent region is pre-formed during manufacturing to the appropriate bend radius and geometry. This preliminary action ensures that during assembly and operation, the wiring component bends along a predetermined safe path that avoids sharp folds or stress concentrations, thereby maintaining reliability while enabling directional flexibility
Data Source
AI summary
A wiring component includes a circuit conductor for each of bus bars and is formed to be flexible and flat. The wiring component includes a wiring main body that runs parallel in an arrangement direction of a battery cells, a wiring intersection body that is connected to one end of the wiring main body in the arrangement direction so as to intersect the arrangement direction on the same plane and protrudes from one side end of the wiring main body along the arrangement direction, and a wiring branch body that is branched from the one side end of the wiring main body for each of the plurality of bus bars, and a bent region provided at one end of the wiring main body is bent to change an insertion/removal direction of a connector attached to a distal end of the wiring intersection body with respect to a mating connector.