Wiring Module Bus Bar Welding for Detection Terminal Integration
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Solution Overview
Problem
Existing wiring modules for power storage systems require costly ultra-high-pressure isostatic environments for metallic bonding of cathode and anode connections, and the process of screwing bolts or nuts is cumbersome, especially when trying to integrate detection terminals without compromising electrical reliability.
Innovation Solution
A wiring module design featuring bus bars with overlapping first and second metal portions that are welded, allowing detection terminals to be connected at flat terminal connection portions distinct from the welded areas, ensuring even surfaces and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic bonding is used to connect cathode and anode connection portions, then electrical connection reliability is improved, but manufacturing cost increases due to ultra-high-pressure isostatic environment requirements
Solution Approach 1:
The invention changes the connection method from metallic bonding (requiring ultra-high-pressure isostatic environment) to welding (using heat and pressure locally at the connection point). This parameter change in the joining process eliminates the need for costly ultra-high-pressure equipment while maintaining electrical connection reliability through direct metal-to-metal contact achieved by welding.
Solution Approach 2:
The invention uses welding, a more economical and widely available joining method, replacing the expensive metallic bonding process. Welding equipment is far more common and cost-effective than ultra-high-pressure isostatic pressing equipment, making the manufacturing process more accessible and cost-efficient while achieving the same functional goal of reliable electrical connection.
2Device complexity
If welding is used to connect bus bar and battery electrodes, then manufacturing complexity is reduced by eliminating screwing tasks, but detection terminal integration becomes problematic
Solution Approach 1:
The invention segments the bus bar into distinct functional zones: a welded portion for connecting to battery electrodes and a separate terminal connection portion for integrating detection terminals. This spatial segmentation allows welding to be applied only where needed for high-current connections, while leaving other areas available for different connection methods, thus maintaining both simplified manufacturing and flexible component integration.
Solution Approach 2:
The invention applies different connection methods to different parts of the bus bar structure. The welded portions provide strong, low-resistance electrical connections for current flow, while the separate terminal connection portions provide accessible, flat surfaces for detecting terminal integration. This local differentiation of connection qualities resolves the conflict between simplified welding processes and versatile terminal integration.
3Strength
If detection terminal is welded to the bus bar at the welded portion, then connection strength is improved, but surface unevenness reduces electrical reliability
Solution Approach 1:
The invention divides the bus bar into functionally distinct segments: welded portions for structural strength and current conduction, and separate flat terminal connection portions for electrical contact with detection terminals. This segmentation ensures that the detection terminals connect to smooth, unevenness-free surfaces, maintaining high electrical reliability while the welded portions provide the necessary mechanical strength.
Solution Approach 2:
The invention creates different surface qualities at different locations on the bus bar. The welded portions have the strength characteristics needed for robust connections, while the terminal connection portions maintain flat, smooth surfaces optimized for low-resistance electrical contact with detection terminals. This local quality differentiation resolves the contradiction between connection strength and electrical reliability.
4Reliability
If multiple bus bars are connected to multiple batteries using screwing methods, then electrical connection reliability is maintained, but task efficiency decreases due to cumbersome screwing operations
Solution Approach 1:
The invention replaces the mechanical screwing system with a welding system for connecting bus bars to battery electrodes. Welding creates permanent, high-strength metallurgical bonds that are equally reliable for electrical connection but can be applied much more quickly and efficiently, especially in automated manufacturing settings, thereby significantly improving task efficiency while maintaining connection reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the reliability of electrical connections between bus bars and detection terminals while reducing manufacturing costs by simplifying the connection process through welding, which also improves task efficiency compared to traditional screwing methods.
Implementation Method 1
the overlapping portions have welded portions at which the first metal portions and the second metal portions are welded
Data Source
AI summary
A wiring module to be attached to a power storage element group in which a plurality of power storage elements having cathodes composed of a first metal and anodes composed of a second metal that is different from the first metal are aligned, includes: bus bars having first metal portions composed of the first metal and second metal portions composed of the second metal; an insulating protector for housing the bus bars; and detection terminals connected to the bus bars. The bus bars have overlapping portions at which portions of the first and second metal portions overlap, the overlapping portions have welded portions at which the first and second metal portions are welded, and the bus bars have terminal connection portions on which the detection terminals are overlaid, at positions different from the positions of the welded portions.