Wiring Module Connector Holder Design
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Solution Overview
Problem
Conventional wiring modules for power storage units face interference issues with connectors dangling outside the resin protector, leading to potential conflicts with other components, and existing solutions like pressure-sensitive adhesive tapes are cumbersome and wasteful.
Innovation Solution
A wiring module design featuring a connector holder integrated into the insulating protector that detachably secures the connector, utilizing an elastic piece and tapered surfaces for easy detachment, protruding wall portions for stability, and a disengagement preventing mechanism for secure holding, reducing the risk of connector interference and simplifying the detachment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connector is held detachably in the connector holder, then the connector is prevented from dangling and interfering with other components, but the device complexity increases due to the additional connector holder structure
Solution Approach 1:
The connector holder is integrated into the insulating protector body, with the holder forming a recessed space within the protector. This nesting approach allows the connector holder to be part of the overall protector structure rather than a separate component, reducing overall device complexity while maintaining the reliability benefit of secure connector holding
Solution Approach 2:
The elastic piece automatically engages with the connector upon insertion and provides automatic retention without requiring additional fastening operations. The elastic deformation and recovery of the piece creates a self-servicing locking mechanism that maintains connector stability passively, eliminating the need for complex active fastening systems
2Reliability
If pressure-sensitive adhesive tape is used to temporarily hold the connector, then the connector interference problem is solved, but time and effort are consumed to remove the tape and the tape becomes waste
Solution Approach 1:
The connector holder extracts the connector from its problematic dangling state outside the protector and positions it within a dedicated recessed space. This extraction eliminates the need for temporary adhesive solutions and their associated time loss, as the holder provides permanent positioning without requiring removal or disposal
Solution Approach 2:
Instead of using disposable adhesive tape that must be removed and discarded, the invention employs a reusable elastic piece that can be inserted and removed multiple times without becoming waste. This eliminates the cumulative waste and time loss associated with repeatedly applying and removing adhesive tape
3Ease of operation
If the elastic piece is made flexible to enable easy detachment, then the detaching operation becomes simple, but the holding strength may be reduced
Solution Approach 1:
The elastic piece transitions between two dynamic states: a deformed state during insertion that allows easy movement, and a recovered state during holding that provides strong retention. The piece dynamically adapts its rigidity based on the operational phase, being flexible during insertion/removal but rigid during the holding phase to maintain connector stability
4Ease of operation
If the connector holder includes disengagement preventing portion and projecting piece, then the connector is securely held and easy to detach even with thick gloves, but the manufacturing complexity increases
Solution Approach 1:
The disengagement preventing portion and projecting piece are merged into a single integrated structure within the connector holder, formed as one continuous feature rather than separate components. This merging reduces the number of manufacturing steps and assembly operations required, offsetting the increased operational functionality with simplified manufacturing
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
The solution effectively prevents connector interference with other components, simplifies the detachment process, and reduces waste by providing a secure and efficient method for managing the connector within the wiring module, ensuring reliable operation and easy handling even with thick gloves.
Implementation Method 1
The connector (70) is held in the connector holder (30) by the elastic piece (73) of the connector (70) being locked to the holding opening (32)
Implementation Method 2
the housing of the connector is pressed against by the protruding wall portion, when compared with, for example, a case without the protruding wall portion, the connector is less likely to slip out of the connector holder
Data Source
AI summary
Provided is a wiring module with which there is no risk that a connector will interfere with other components in a state in which the connector is not connected to an external device. A wiring module to be attached to a power storage element group in which a plurality of power storage elements are lined up includes a bus bar for electrically connecting the plurality of power storage elements together, an insulating protector that accommodates the bus bar and is to be mounted onto the power storage element group, a wire that extends from the bus bar to the outside of the insulating protector, a connector that is provided at an extending end portion of the wire, the extending end portion extending from the insulating protector, and a connector holder that is provided in the insulating protector and detachably holds the connector.