Segmented Battery Wiring Module for Pitch Deviation
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Solution Overview
Problem
Conventional battery wiring modules are inflexible and require significant force to adjust slit sizes to accommodate deviations in electrode terminal pitch, leading to assembly challenges and reduced workability when connecting to battery groups.
Innovation Solution
A battery wiring module with elongated terminal through holes and bus bars, allowing for curvature and independent connection of bus bars to electrode terminals, along with insulation walls and a stopper system to improve assembly efficiency and accommodate pitch deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a single synthetic resin plate is used to form the battery wiring module, then the module is less likely to be curved as a whole, but it becomes difficult to accommodate deviations in electrode terminal pitch and reduces assembling workability
Solution Approach 1:
The battery wiring module is divided into multiple connection units that are connected together. Each connection unit includes a bus bar and a bus bar housing, allowing the module to be segmented into flexible sections that can be independently positioned and connected to accommodate pitch deviations while maintaining overall structural stability.
Solution Approach 2:
The connection units are designed to be movable relative to each other, allowing the battery wiring module to dynamically adjust its configuration during assembly. This enables the module to accommodate deviations in electrode terminal pitch by adjusting the positions of individual connection units rather than requiring the entire module to be rigidly fixed.
2Adaptability or versatility
If slits are formed in the synthetic resin plate to absorb pitch deviations, then the deviation can be accommodated, but a relatively great force is required to increase or reduce the slit size
Solution Approach 1:
Instead of forming slits in a single rigid plate, the module is segmented into multiple connection units that can move independently. This eliminates the need to apply great force to deform a rigid plate while still providing adaptability to pitch deviations through the relative movement of segments.
Solution Approach 2:
The connection units are designed with movable connections that allow easy adjustment of positions to absorb pitch deviations. This dynamic configuration requires minimal force to adjust compared to deforming a rigid plate with slits, as the movable joints naturally accommodate dimensional variations.
3Device complexity
If all bus bars are connected to all electrode terminals at the same time, then the connection is simplified, but the module cannot accommodate pitch deviations in different portions
Solution Approach 1:
The battery wiring module is divided into multiple connection units, each capable of being connected to electrode terminals independently. This segmentation allows different portions of the module to accommodate local pitch deviations while maintaining a relatively simple connection process within each unit.
Solution Approach 2:
The movable connection units can be independently positioned and connected to electrode terminals, allowing the assembly process to accommodate pitch deviations in different portions without requiring complex adjustments to the entire module. Each unit can be connected at its optimal position while others adjust accordingly.
Data Source
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AI summary
A battery wiring module 14 is configured to be attached to a battery group 13 including a plurality of batteries 12 each having electrode terminals 11 including a positive electrode terminal and a negative electrode terminal and configured to connect the electrode terminals 11. The battery wiring module 14 includes a plurality of connection units 16 connected to each other in a battery arrangement direction in which the batteries 12 are arranged. Each of the connection units 16 includes a bus bar 17 and a bus bar housing 19. The bus bar 17 is configured to connect one of the electrode terminals 11 of one of the batteries 12 and one of the electrode terminals 11 of another one of the batteries 12. The bus bar housing 19 houses the bus bar 17. The bus bar 17 has a pair of terminal through holes 18 configured to receive the electrode terminals 11 and each of the terminal through holes 18 is formed in a shape elongated in the battery arrangement direction.