Segmented Insulating Cover for Power Storage Modules
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Solution Overview
Problem
The complexity in the shape of insulating covers for power storage modules, particularly where non-flat surfaces are present, increases production costs due to the need for customized shapes and complicates the assembly process.
Innovation Solution
A wiring module design featuring multiple division covers with the same shape, allowing for easy assembly and reduced production costs by using a common mold, with cut portions to accommodate external connection covers and auxiliary covers to maintain a closed state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single insulating cover is used to cover the insulating protector, then the insulation is complete, but the assembling operation becomes difficult and production cost increases due to complex shape requirements
Solution Approach 1:
The insulating cover is divided into multiple division covers (first division cover, second division cover, etc.) that can be assembled separately and then combined. Each division cover has a simpler shape that can be easily manufactured and assembled, while collectively they provide complete insulation coverage of the insulating protector.
2Reliability
If the insulating cover shape is customized to match non-flat surfaces, then insulation coverage is improved, but production cost increases due to complex mold requirements
Solution Approach 1:
The insulating cover is segmented into multiple division covers with standardized, simpler shapes that can be manufactured using common molds. The segmentation allows each piece to have a uniform geometry that is easier and more cost-effective to produce, while the collective arrangement provides the necessary coverage for non-flat surfaces.
Solution Approach 2:
The division covers are designed with universal applicability - they can be used to cover various non-flat surface configurations by arranging multiple identical or similar components. This standardization enables the use of common molds for production, reducing manufacturing costs while maintaining adaptability to different insulating protector shapes.
3Ease of operation
If multiple division covers are used to simplify assembly, then assembling operation is facilitated, but the number of parts increases
Solution Approach 1:
The insulating cover is divided into a limited number of division covers (typically 2-4 pieces) that strike a balance between ease of assembly and part quantity. This segmentation allows for simplified assembly operations while keeping the total number of parts manageable and reasonable for the application.
Data Source
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AI summary
A wiring module 20 includes connecting members 21 for electrically connecting electrode terminals 12A, 12B of adjacent power storage elements 11, an insulating protector 30 for accommodating the connecting members 21 and an insulating cover 50 for covering the insulating protector 30. The insulating cover 50 is configured by arranging a plurality of division covers 51A to 51C, at least one division cover 51 B, 51C of adjacent ones of the plurality of division covers 51A to 51C is formed with an overlapping portion 55 to be overlapped with the adjacent division cover 51A, 51 B.