Folded Voltage-Sensing Wiring Module for Battery Terminal Alignment
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Solution Overview
Problem
The existing wiring modules for power storage devices face challenges in aligning voltage detection lines with electrode terminals in a manner that reflects the potential order, leading to increased complexity and manufacturing costs due to the need for jumper wires.
Innovation Solution
A wiring module design featuring two rows of electrode terminals with flexible substrates having voltage detection lines folded odd or even numbers of times to align ends in the order of potentials, connected via a common connector, allowing for cost-effective arrangement of voltage detection lines on a single surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If jumper wires are used to arrange voltage detection lines in the order of potential, then the voltage detection lines can be aligned in the order of potential, but the number of components and wiring complexity increases, leading to increased manufacturing cost
Solution Approach 1:
The flexible substrate is divided into multiple regions with voltage detection lines arranged in different patterns (first pattern for even-numbered lines, second pattern for odd-numbered lines). This segmentation allows each region to be optimized independently, achieving proper alignment without requiring additional jumper wires to connect scattered lines.
Solution Approach 2:
The patent transitions from a single-linear arrangement to a two-dimensional arrangement where voltage detection lines are organized in multiple rows and columns on the flexible substrate. This dimensional change enables lines to reach their target terminals more directly, eliminating the need for jumper wires while maintaining proper potential order alignment.
2Ease of manufacture
If voltage detection lines are arranged irrespective of potential order, then the wiring is simpler, but the alignment with the device terminals (which are formed in the order of potential) is incorrect
Solution Approach 1:
Different regions of the flexible substrate are assigned different line arrangement patterns optimized for their specific connection requirements. Even-numbered voltage detection lines follow a first arrangement pattern while odd-numbered lines follow a second pattern, allowing each line to reach its target terminal efficiently while maintaining overall potential order alignment.
Solution Approach 2:
The voltage detection lines are pre-arranged in the correct potential order on the flexible substrate during manufacturing, rather than requiring post-manufacturing adjustment with jumper wires. This preliminary arrangement ensures proper alignment is built into the structure from the start.
3Device complexity
If a single flexible substrate is used for all voltage detection lines, then the structure is simpler, but it is difficult to achieve proper alignment when lines need to be folded
Solution Approach 1:
The voltage detection lines are divided into two groups (even-numbered and odd-numbered) that are arranged in different patterns on the same flexible substrate. This logical segmentation allows complex routing requirements to be satisfied while using a single physical substrate, avoiding the need for multiple separate substrates.
Data Source
AI summary
A wiring module is attached to a plurality of power storage devices, electrode terminals of the plurality of power storage devices being arranged in two rows continuously in an aligning direction of the plurality of power storage devices, and the two rows of electrode terminals being separated from each other in a separation direction orthogonal to the aligning direction, the wiring module including: a first substrate that is flexible and has a plurality of first voltage detection lines on only one surface thereof, a second substrate that is flexible and has a plurality of second voltage detection lines on only one surface thereof, and a connector, the plurality of first voltage detection lines are folded an odd number of times, ends on one side of the first voltage detection lines are electrically connected to electrode terminals that form one row of the two rows of electrode terminals.