Wiring Module Bus Bar Beam Positioning for Power Storage
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Solution Overview
Problem
The existing technologies for connecting power storage device electrode terminals to bus bars, as described in JP 2016-207584A and JP 2011-8957A, result in unreliable electrical connections due to misalignment of bus bar contact positions, leading to decreased reliability.
Innovation Solution
A wiring module configuration where bus bars with bent portions are positioned on beam portions within insulating protectors, ensuring accurate height setting and improved alignment, and through-holes are used to secure the bus bars, enhancing position accuracy and reliability of electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bus bar is placed on the beam portion at the intermediate position between through-holes, then the bus bar holding structure is simplified, but the contact portion height position cannot be accurately set
Solution Approach 1:
The patent introduces a beam portion as an intermediary component between the bus bar holding structure and the contact portions. The beam portion serves as a mediator that enables accurate height positioning of contact portions while maintaining structural simplicity. The beam portion is positioned at the intermediate location between through-holes and provides a stable support surface for the contact portions, resolving the conflict between structural simplicity and positioning accuracy.
2Ease of operation
If the bus bar holding portion enters the bridge portion, then the bus bar can be held, but the height position of contact portions cannot be accurately set
Solution Approach 1:
The patent segments the bus bar structure into distinct functional portions: bridge portions for stress relief and connection, contact portions for electrical contact, and positioning portions for accurate placement. This segmentation allows each portion to perform its specific function optimally - the bridge portion handles mechanical stress while the contact portions maintain accurate height positioning on the beam portion, preventing interference and ensuring reliable electrical connections.
3Reliability
If bus bars are individually connected to electrode terminals, then electrical connection is achieved, but extremely troublesome work needs to be repeated
Solution Approach 1:
The patent merges multiple bus bars into a single integrated bus bar structure that can simultaneously connect to multiple electrode terminals. The bus bar includes multiple contact portions that can be connected to respective electrode terminals in one operation, eliminating the need for repeated individual connection operations. This merging approach maintains reliable electrical connections while dramatically improving assembly efficiency.
Data Source
AI summary
The reliability of electrical connection between electrode terminals of power storage devices and bus bars can be improved. A bent portion that is provided on each bus bar is formed at a position shifted in the left-right direction from an intermediate position between one contact portion of two contact portions of the bus bar and the other contact portion positioned next to the one contact portion. In a bus bar housing portion, a beam portion on which a corresponding bus bar is placed is formed extending in the front-rear direction. Each beam portion is formed at a position shifted in the left-right direction from the bent portion in a state where the bus bar is housed in the bus bar housing portion.