Slidable Wiring Module Coupling Units for Battery Mounting
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Solution Overview
Problem
Dimensional errors between the wiring module and other portions of electric cells, aside from electrodes, can lead to mounting failures in battery modules for electric and hybrid cars, as existing technologies primarily focus on pitch errors between electrode terminals.
Innovation Solution
A wiring module design featuring connecting members that connect electrode terminals and a resin protector with slidable coupling units, including extension portions to accommodate dimensional inaccuracies, allowing for positional adjustment and improved workability during mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If connecting members are rigidly fixed to the substrate, then structural stability is improved, but mounting adaptability deteriorates due to dimensional errors
Solution Approach 1:
The connecting members are designed with slidable coupling units that allow relative movement along the connecting members. This dynamic structure enables the wiring module to adapt to dimensional errors between the wiring module and electric cells while maintaining structural stability during operation. The coupling units can slide to accommodate pitch variations, transforming the rigid structure into a semi-dynamic one that combines stability with adaptability.
2Adaptability or versatility
If multiple coupling units are used to enhance adaptability, then mounting flexibility is improved, but device complexity increases
Solution Approach 1:
The resin protector is divided into multiple coupling units that are coupled via the connecting members. Each coupling unit can independently slide along the connecting members, providing localized adaptability. This segmentation allows the system to achieve mounting flexibility without requiring a complete redesign of the entire structure, thereby limiting the increase in device complexity.
Solution Approach 2:
The coupling units are nested within the resin protector structure, with each coupling unit integrated into the overall wiring module assembly. The coupling units are positioned along the connecting members in a nested arrangement, allowing them to slide independently while maintaining a compact overall structure. This nesting approach minimizes the increase in device complexity.
3Manufacturing precision
If the wiring module is designed for precise dimensional accuracy, then mounting precision is improved, but ease of operation deteriorates due to strict alignment requirements
Solution Approach 1:
The design allows for parameter changes in the form of slidable coupling units that can adjust their position along the connecting members. This enables the wiring module to accommodate dimensional variations without requiring strict alignment during mounting. The coupling units can slide to compensate for pitch errors, transforming a precision-critical assembly into a more operationally flexible process.
Data Source
AI summary
Adjacent coupling units of a plurality of coupling units are slidably coupled via connecting members in a connection direction of the connecting members. Of the plurality of coupling units, one coupling unit of adjacent coupling units that are not coupled to each other via the corresponding connecting member includes an extension portion that is extended toward another connecting member that is different from the connecting member that couples the one coupling unit. The extension portion holds the other connecting member.