Wiring Module Bus Bar Orientation for Thin Overcurrent Protection
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Solution Overview
Problem
Conventional battery modules for electric vehicles and hybrid vehicles face challenges in realizing a thin wiring module with overcurrent protection devices, as they require space for these devices, making it difficult to achieve a compact design.
Innovation Solution
A wiring module configuration that includes a bus bar to connect adjacent electricity storage devices, an overcurrent protection device integrated with the bus bar, and a housing design allowing the protection device to be oriented along the bus bar's direction, reducing the module's thickness by allowing the overcurrent protection devices to be placed along the bus bar's length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overcurrent protection devices are disposed in a conventional wiring module, then overcurrent protection function is provided, but the module thickness increases
Solution Approach 1:
The patent changes the orientation of the overcurrent protection device from a vertical arrangement (increasing thickness) to a horizontal arrangement along the bus bar's length. The protection device is disposed to extend in the longitudinal direction of the bus bar, utilizing the length dimension instead of the thickness dimension, thereby achieving thin-profile wiring modules while maintaining protection functionality.
Solution Approach 2:
Instead of placing the overcurrent protection device perpendicular to the bus bar (conventional approach), the patent inverts the arrangement by placing it parallel to and along the bus bar's length. This inversion of the spatial relationship between the protection device and bus bar resolves the thickness issue while preserving the protection function.
2Reliability
If electrical wires are routed through the wiring module, then electrical connection is achieved, but wire handling and routing becomes complex
Solution Approach 1:
The patent segments the wiring module into basic units, each with dedicated wire routing paths. Electrical wires are guided through designated spaces between the bus bar and housing, creating organized, separate routing channels for each wire. This segmentation simplifies wire handling by providing clear, predetermined paths rather than requiring complex three-dimensional routing.
3Length of moving object
If the wiring module is made thin, then space efficiency is improved, but overcurrent protection devices cannot be properly disposed
Solution Approach 1:
The overcurrent protection device is nested within the housing structure, with the device body positioned in the internal space of the housing and only necessary connection portions extending outward. The device is integrated into the housing cavity, utilizing the available internal volume efficiently, which allows thin-profile modules to accommodate protection devices without compromising manufacturability.
Data Source
AI summary
A wiring module that is to be attached to a unit cell group in which a plurality of unit cells that each have positive and negative electrode terminals are arranged, including a plurality of basic units arranged in a direction in which the unit cells are arranged. Each of the plurality of basic units includes: a bus bar configured to electrically connect the electrode terminals of two adjacent unit cells to each other; an electrical wire that is to be electrically connected to the unit cells to detect a state of the unit cell group; a fuse configured to electrically connect the bus bar and the electrical wire to each other, and prevent an overcurrent; and a housing provided with a fuse opening into which the fuse is inserted, and a bus bar opening into which the bus bar is inserted. The fuse opening opens in a direction in which the bus bar extends.