Integrated Wiring Module for Battery Assembly Simplification
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Solution Overview
Problem
The assembly of wiring components in battery assemblies is time-consuming due to the need for individual bus bars, voltage detection wirings, and crimping terminals, which can be simplified to reduce complexity and cost.
Innovation Solution
A wiring module with an insulating resin substrate featuring a terminal pattern connected to battery electrodes, a voltage detection wiring pattern, and a fuse pattern, all integrated on the substrate with through-holes for electrode insertion, eliminating the need for crimping terminals and allowing for space-saving and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual bus bars, voltage detection wirings, and crimping terminals are used separately, then reliable electrical connection is achieved, but assembly time increases proportionally with the number of battery series
Solution Approach 1:
The patent combines multiple separate wiring components (bus bar, voltage detection wiring, and crimping terminal) into a single integrated wiring component. The terminal pattern is formed on an insulating substrate with through-holes that directly receive battery electrodes, eliminating the need for separate crimping terminals and reducing assembly steps while maintaining reliable electrical connections.
Solution Approach 2:
The integrated wiring component performs multiple functions simultaneously: it provides electrical connection (bus bar function), voltage detection (wiring function), and mechanical retention (terminal function) all in one component. This multi-functional design reduces the number of parts and simplifies the assembly process.
2Adaptability or versatility
If multiple separate wiring components are used, then functional requirements are met, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple wiring components into a single integrated structure where the terminal pattern with through-holes combines the functions of bus bars, voltage detection wirings, and crimping terminals. This reduces device complexity by eliminating the need for multiple separate components while maintaining all necessary wiring functionalities.
3Reliability
If multiple separate wiring components are used, then electrical connection is achieved, but weight and cost of wiring increase
Solution Approach 1:
The patent combines multiple wiring components into one integrated wiring component, reducing the total amount of material required. The insulating substrate with integrated terminal patterns eliminates redundant materials from separate components and their connections, thereby reducing overall wiring weight while maintaining reliable electrical connections.
4Ease of operation
If adjacent bus bars are connected through insulating members, then mounting work is simplified, but assembly time still increases with battery series count
Solution Approach 1:
The patent integrates the insulating substrate and terminal patterns into a single component that performs both insulation and electrical connection functions simultaneously. The through-holes in the terminal pattern directly receive battery electrodes, eliminating the need for separate insulating members and further reducing assembly time proportional to the number of battery series.
Data Source
AI summary
A wiring module that is used in a battery assembly in which a columnar positive electrode and a columnar negative electrode of a plurality of batteries formed in a thin-type rectangular parallelepiped shape are arranged alternately. The wiring module includes a terminal pattern on a surface of an insulating resin substrate connected to the columnar positive electrode and the columnar negative electrode; a voltage detection wiring pattern on the surface connected to the terminal pattern; a fuse pattern on the surface interposed in the voltage detection wiring pattern; and an insulating resin layer that covers a peripheral portion of the terminal pattern, the voltage detection wiring pattern, and the fuse pattern are covered with the insulating resin layer A pair of through-holes, into which the columnar positive electrode and the columnar negative electrode are inserted, is formed in the terminal pattern and the insulating resin substrate.