Wiring Module Cover Pressing Portion for Battery Temperature Sensor
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Solution Overview
Problem
The existing methods for connecting bus bars and electrode terminals in power storage modules for electric vehicles require additional fastening members for temperature sensors, increasing the number of parts and work steps, especially when using laser welding.
Innovation Solution
A wiring module configuration that includes a bus bar, a temperature detection member with a plate-shaped detection portion, an insulating protector, and a cover with a pressing portion that holds the detection member in place without the need for additional fastening members, allowing for laser welding connections between the bus bar and electrode terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fastening member is added to fix the temperature detection member to the bus bar when using laser welding, then the temperature sensor can be fixed, but the number of parts increases and separate fixing work is required
Solution Approach 1:
The pressing portion is integrated into the cover structure, merging the fixing function with the existing cover component. This eliminates the need for separate fastening members while maintaining the temperature sensor fixation capability, directly resolving the contradiction between reliability and device complexity
Solution Approach 2:
The cover is designed to serve multiple functions: it provides protection, houses the pressing portion for sensor fixation, and integrates with the laser welding process. This multi-functionality reduces the need for additional dedicated components, addressing both the fixation requirement and the reduction of part count
2Reliability
If a fastening member is added to fix the temperature detection member to the bus bar, then the temperature sensor can be fixed, but separate fixing work is required
Solution Approach 1:
The fixing function is merged into the cover assembly process. The pressing portion is built into the cover, so that a single assembly operation accomplishes both cover installation and temperature sensor fixation, eliminating separate fixing steps and improving productivity
Solution Approach 2:
The pressing portion is pre-integrated into the cover structure before assembly. This preliminary design ensures that the fixing capability is already in place, eliminating the need for additional fixing operations during assembly and streamlining the manufacturing process
3Measurement precision
If the detection portion overlaps the bus bar region that overlaps the electrode terminals, then temperature detection is effective, but the bus bar and electrode terminal connection is blocked
Solution Approach 1:
The detection portion is positioned to overlap only the non-terminal region of the bus bar, creating a localized temperature measurement zone that does not interfere with the terminal connection area. This local differentiation allows effective temperature detection while maintaining manufacturing accessibility for laser welding
Solution Approach 2:
The detection portion is arranged in a specific spatial relationship with the bus bar, overlapping a region that is offset from the electrode terminal connection zone. This dimensional arrangement allows the detection function to operate in one area while leaving the welding area accessible, resolving the contradiction between measurement precision and ease of manufacture
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 configuration reduces the number of parts and work steps required, providing a more efficient and streamlined assembly process while maintaining effective temperature detection and electrical connectivity.
Implementation Method 1
a pressing portion that presses the detection portion toward the bus bar in a state where the cover is covering the insulating protector is provided on the cover
Implementation Method 2
a temperature detection member that has a plate-shaped detection portion that overlaps the bus bar, and detects a temperature of the bus bar
Data Source
AI summary
A wiring module to be attached to a unit battery group in which a plurality of unit batteries, each having a positive and a negative electrode terminal, are arranged side by side, the wiring module including: a bus bar that overlaps the electrode terminals and electrically connects adjacent electrode terminals; a temperature detection member having a plate-shaped detection portion that overlaps the bus bar, and detects the temperature of the bus bar; an insulating protector holding the bus bar and the temperature detection member; and a cover covering at least a portion of the insulating protector. The detection portion overlaps a region of the bus bar other than a region of the bus bar that overlaps the electrode terminals, and a pressing rib that presses the detection portion toward the bus bar in a state where the cover is covering the insulating protector is provided on the cover.