Wiring Module Insulating Protector Vibration Alignment

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Solution Overview

Problem

Existing wiring modules face connection failures and rattling issues due to misalignment and differential behavior under external forces, such as vibration, between abnormality detection elements and conductors, leading to potential load application on connected parts.

Innovation Solution

A wiring module design that integrates an insulating protector with conductor and element holding portions, using tapered and elongated fittings to securely position and fix both the connection conductor and abnormality detection element, preventing misalignment and rattling through precise alignment and pinching mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the conductor is fixed to the case and the fuse is fixed to the cover to integrally hold them, then the conductor and fuse are securely positioned, but the connection terminal may deviate from the regular position in the circumferential direction due to conductor rotation during assembly

Engineering Contradiction:

Improvepositioning stabilityVSAvoidterminal alignment precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The conductor holding portion and element holding portion are integrated into a single insulating protector component, ensuring that both the conductor and abnormality detection element are positioned and held together as a unified structure, preventing relative movement and misalignment between connected terminals

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating protector preliminarily positions both the conductor and abnormality detection element in their correct relative positions before final assembly, preventing rotation and misalignment from occurring during subsequent assembly steps

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the terminals of the conductor and fuse are connected, then electrical connection is established, but rattling occurs under vibration due to clearance from accumulated tolerances

Engineering Contradiction:

Improveconnection reliabilityVSAvoidvibration-induced rattling

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Both the conductor and abnormality detection element are held by the same insulating protector, eliminating clearance between them and preventing rattling under vibration, while maintaining secure electrical connection

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Instead of allowing separate fixation of conductor and element to different components (case and cover), the invention inverts the approach by fixing both to a single insulating protector, thereby eliminating the clearance issues caused by accumulated tolerances

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If the conductor rotates during assembly, then the conductor can be inserted into the case, but the connection terminal deviates from the regular position causing potential connection failure

Engineering Contradiction:

Improveassembly easeVSAvoidterminal position precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The insulating protector preliminarily secures the conductor in its correct position and orientation before assembly is completed, preventing rotation during the assembly process while still allowing easy insertion into the case

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11502432B2Wiring module

Publication Date: 2022.11.15 AUTONETWORKS TECH LTD

AI summary

A wiring module to be attached to a plurality of power elements which store or generate power includes a bus bar connecting the power elements to each other or connecting the power element and a load to each other, an abnormality detection element detecting an abnormality of the power element, and an insulating protector holding the bus bar and the abnormality detection element. The insulating protector is integrally provided with a first holding shaft portion and a second holding shaft portion which position and hold the bus bar by fitting the bus bar there onto, and an element holding portion which position and hold the abnormality detection element by fitting the abnormality detection element there into.