Insulating Protector Clearance Design for Power Storage Module Vibration
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Solution Overview
Problem
In power storage modules for vehicles, the insulating protector can move relative to the power storage elements due to vibration, potentially causing deformation or damage to the bus bars as it applies a load through the electrical wires.
Innovation Solution
The power storage module design includes an insulating protector with opposing and withdrawal restriction portions that have specific clearances, and a restriction portion that limits movement relative to the power storage elements, preventing contact with the connection members and thus suppressing the application of load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating protector is designed with clearances to allow relative movement, then the protector can accommodate vibration without damaging the connection member, but the protector may move excessively and apply load to the connection member
Solution Approach 1:
The patent applies parameter changes by introducing a restriction portion with a specific clearance (second clearance) that is smaller than the initial clearance (first clearance) between the protector and connection member. This parameter change limits the movement distance of the protector, ensuring it cannot exceed the safe range that would cause contact with the connection member, thus resolving the contradiction between allowing vibration accommodation and preventing excessive movement.
Solution Approach 2:
The restriction portion acts as an intermediary element between the insulating protector and the connection member. It mediates the movement of the protector by providing a physical barrier at a controlled distance, preventing the protector from contacting the connection member while still allowing sufficient movement range to accommodate vibration, thus protecting the connection member without completely restricting protector mobility.
2Reliability
If the insulating protector is rigidly fixed to prevent movement, then the connection member is protected from load application, but the protector cannot accommodate vibration and may transmit stress to the connection member
Solution Approach 1:
The patent changes the movement parameter of the protector by introducing a controlled clearance (second clearance) between the restriction portion and the connection member. This allows the protector to move within a safe range to accommodate vibration, while the restriction portion prevents movement beyond this range, thus eliminating both rigid fixation and excessive movement.
Solution Approach 2:
The restriction portion provides beforehand cushioning by being positioned at a predetermined distance (second clearance) from the connection member. This creates a safety buffer zone that absorbs the vibration movement before it can reach the connection member, preventing stress transmission while allowing controlled movement.
3Ease of operation
If the clearance between the protector and connection member is large, then the protector can move freely during vibration, but the opposing portion and withdrawal restriction portion may contact the connection member and apply load
Solution Approach 1:
The patent applies parameter changes by establishing a specific relationship between two clearances: the first clearance (between protector and connection member) and the second clearance (between restriction portion and connection member). The second clearance is designed to be smaller than the first clearance, creating a hierarchical clearance system that limits protector movement to prevent contact between the opposing/withdrawal restriction portions and the connection member, thus protecting connection member integrity while maintaining movement freedom.
Solution Approach 2:
The restriction portion performs preliminary action by restricting the protector's movement range before the opposing portion or withdrawal restriction portion can contact the connection member. This preliminary restriction prevents the harmful contact from occurring in the first place, maintaining both movement freedom and connection member strength.
Data Source
AI summary
A power storage module includes multiple power storage elements that each have cathode and anode electrode portions, connection members that connect the cathodes and anodes of the power storage elements and are fixed to the power storage elements by a fixing means, and an insulating protector that houses the connection members. The insulating protector includes opposing portions that oppose surfaces of the connection members, and withdrawal restriction portions that restrict withdrawal of the connection members from the other surface side. At least one of the opposing portions and the withdrawal restriction portions have a first clearance with respect to the connection members. The insulating protector further includes restriction portions that restrict movement relative to the power storage elements by an amount greater than or equal to a second clearance that is smaller than the first clearance.