Hinged Cover Busbar Module Prevents Wire Wear
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Solution Overview
Problem
The existing busbar module structures face issues with power cables and voltage detection wires intersecting, leading to potential wear and exposure of voltage detection wire conductors due to vibration, and result in complex designs that are difficult to manufacture and increase the module size.
Innovation Solution
A busbar module unit design where a cover member with a hinge portion is integrated with the busbar module, allowing it to fold back and interpose between the connection terminal and voltage detection wires, preventing contact and wear, while maintaining a simpler structure by routing the wires in opposite directions and using ribs and grooves to guide the wires correctly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power cable and voltage detection wires are routed in opposite directions to avoid intersection, then the risk of contact and wear is reduced, but the routing complexity and space requirements increase
Solution Approach 1:
The patent introduces a cover member as an intermediary component that physically separates the voltage detection wires from the connection terminals. The cover member includes a wiring path for the voltage detection wires and a terminal accommodating portion for the connection terminals, creating a protective barrier that prevents direct contact and eliminates the need for complex opposite-direction routing.
Solution Approach 2:
The busbar module structure is segmented into distinct functional zones: the wiring path for voltage detection wires and the terminal accommodating portion for power cable terminals. This segmentation is achieved through the cover member that divides the internal space, allowing independent routing of different wire types without interference.
2Reliability
If the accommodation part for connection terminals is formed to extend over the wiring path, then contact between terminals and wires is avoided, but the structure becomes complex and difficult to manufacture as one piece
Solution Approach 1:
The cover member is designed with a hinge portion that enables it to be folded back during the injection molding process. This dynamic feature allows the cover member to be temporarily opened to accommodate the busbar module, then folded back to its protective position after assembly, enabling one-piece manufacturing while maintaining the extended accommodation structure for terminal protection.
3Reliability
If the accommodation part for connection terminals is formed to extend over the wiring path, then contact between terminals and wires is avoided, but the size of the busbar module increases
Solution Approach 1:
The cover member utilizes the thickness dimension of the busbar module by extending over the wiring path in the vertical direction rather than expanding the horizontal footprint. This dimensional approach allows the terminal accommodation portion to protect wires from terminals without significantly increasing the overall module volume, as the extension occurs in the z-axis direction.
Data Source
AI summary
A busbar module unit includes a busbar module that is made of a resin and retains a plurality of first conductors and two second conductor, a wiring path that accommodates a plurality of voltage detection wires, a terminal accommodating portion that accommodates connection terminals of a power cable, and a cover member that is connected to the busbar module via a hinge portion. The terminal accommodating portion is integrally formed with the cover member. The wiring path is arranged so as to intersect at least one of the connection terminals. The cover member has a first face and a second face opposite to the first face, the first face opposes the wiring path when the cover member is folded back via the hinge portion. The terminal accommodating portion is formed on the second face.