Integrated Circuit Unit Housing for Compact EV Battery Packs
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Solution Overview
Problem
The existing structure for in-vehicle electric components requires additional work processes and increased space for connecting circuit units to connectors, leading to larger battery pack sizes.
Innovation Solution
An in-vehicle electric component-internal circuit unit with a novel structure that includes an insulative holder, a wire harness with a cylindrical grommet, and a plate wall portion with an annular seal member, allowing the connector to be pre-connected to the circuit member and reducing the need for external connection work, thereby minimizing the number of work processes and component size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If connectors are provided on the housing and circuit units are connected externally, then connection flexibility is improved, but the number of work processes increases and component size increases
Solution Approach 1:
The patent combines the connector and circuit unit into a single integrated assembly where the connector is directly mounted on the circuit unit housing rather than being separate on the main housing. This merging eliminates the need for separate connection work processes while maintaining connection flexibility, directly resolving the technical contradiction between adaptability and device complexity.
2Adaptability or versatility
If connectors are provided on the housing and external connection work is performed, then connection flexibility is improved, but component size increases due to required workspace
Solution Approach 1:
By integrating the connector directly onto the circuit unit housing, the patent eliminates the need for external workspace between separate connectors and circuit units. This reduces the overall battery pack volume while preserving connection flexibility, resolving the contradiction between adaptability and component size.
3Ease of manufacture
If multiple separate components are used for connection, then ease of manufacture is improved, but the number of work processes increases
Solution Approach 1:
The patent merges the connector and circuit unit into an integrated assembly that can be manufactured as a single unit or pre-assembled module. This approach maintains the manufacturing advantages of standardized components while dramatically improving assembly efficiency by eliminating multiple separate connection work processes, thus resolving the contradiction between ease of manufacture and productivity.
Data Source
AI summary
An in-vehicle electric component-internal circuit unit has a novel structure that can reduce the number of in-vehicle electric component-side work processes and reduce in-vehicle electric component size. An in-vehicle electric component-internal circuit unit includes: an insulative holder that holds circuit members; a wire harness that includes a coated wire, a circuit-side connection portion that is provided on an end portion on one side of the coated wire, a connector that is provided on an end portion on the other side of the coated wire, and a grommet through which the coated wire passes; a plate wall portion for covering a housing through-hole provided in a housing of an in-vehicle electric component; and a seal member that is provided on a first surface, which is a surface of the plate wall portion to be attached to the housing and that comes into contact with the rim of the housing through-hole.