Finger-resistant terminal arrangement for high voltage applications

Abstract

The present invention also relates to a finger-proof terminal arrangement for high voltage applications. A terminal arrangement for a high voltage battery is disclosed. The terminal arrangement comprises a substrate having concentric, generally tubular inner and outer walls extending from an upper surface of the substrate, with an annular terminal disposed on the upper surface between the inner and outer walls. The inner and outer walls have respective inner and outer heights above a top surface of the annular terminal, and the annular terminal has a radial span between the inner and outer walls, wherein the inner and outer heights and the radial span are dimensioned to prevent a fingertip of a human beyond a predetermined size from contacting the annular terminal.

Description

Background Technology

[0001] Batteries are typically connected together to form battery packs. Potential problems with discrete batteries or battery packs with high voltage involve the safety of human operators handling such batteries. For example, one issue is that a human operator might inadvertently touch one or more exposed battery terminals and receive an electric shock. Another issue is that wrenches or other metal tools might be accidentally dropped or placed against one or more exposed battery terminals by a human operator or assembly robot, causing an arc or discharge.

[0002] These issues are typically addressed by covering the terminals with plastic caps (e.g., during battery transport and storage) to prevent human operators from accidentally touching the terminals or tools from coming into contact with them. However, providing such terminal caps increases costs, part count, and recycling / landfill waste issues, and they must also be removed before the connector is fastened to the terminals. Summary of the Invention

[0003] According to one embodiment, a terminal arrangement structure includes a substrate made of a first electrically insulating material and having an upper surface. A generally tubular inner wall extends from the upper surface at its first end and terminates at its second end opposite the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius away from the central axis of the inner wall, and an annular lip extending inward from the second end. A generally tubular outer wall extends from the upper surface at its third end and terminates at its fourth end opposite the third end, wherein the outer wall is made of a third electrically insulating material and has an outer radius greater than the inner radius extending from the central axis, wherein the outer wall is concentric with the inner wall. A conductive annular terminal is disposed on top of the upper surface and surrounds the inner wall between the inner wall and the outer wall. The conductive tubular terminal extends through an aperture formed in the upper surface of the substrate and has an outer circumferential surface disposed to contact the inner circumferential surface of the inner wall.

[0004] In this embodiment, the outer wall is attached to the substrate in such a way that the substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions snap into corresponding grooves in the first plurality of grooves, or the outer wall is molded as part of the substrate. Additionally, the inner wall is attached to the substrate in at least one of the following ways: (i) the substrate has a third plurality of grooves formed in the upper surface, and the inner wall has a fourth plurality of protrusions extending radially outward from the first end, wherein the fourth plurality of protrusions snap into corresponding grooves in the third plurality of grooves; (ii) the inner wall is press-fitted to the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on the outer circumferential surface that are wider than the orifice to prevent the lower portion of the tubular terminal from passing through the orifice; and (iii) the inner wall is molded as part of the substrate.

[0005] The first plurality of grooves, the second plurality of protrusions, the third plurality of grooves, and the fourth plurality of protrusions may each be arranged circumferentially around the central axis. The inner wall may be molded as part of the substrate and may cover at least a portion of the tubular terminal. Furthermore, the outer wall may be molded as part of the substrate and may include a plurality of outer wall segments arranged circumferentially around the central axis. The inner wall and the outer wall may have corresponding inner and outer heights above the top surface of the annular terminal, and the annular terminal may have a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span dimensions are set to prevent fingertips of a person exceeding a predetermined size from contacting the annular terminal. Additionally or alternatively, the annular lip may have an annular lip thickness and may define an annular hole with an annular hole diameter, wherein the annular hole diameter and the annular lip thickness dimensions are set to prevent fingertips of a person exceeding a predetermined size from contacting the tubular terminal.

[0006] The second and third electrical insulating materials may be the same, or the first, second, and third electrical insulating materials may be the same. The terminal arrangement may further include a dielectric layer covering the substrate and having a window formed therein, through which corresponding portions of the inner wall, the outer wall, and the tubular terminal protrude. The terminal arrangement may also include electrical wiring carried by the substrate and operatively connected to at least one of the annular terminal and the tubular terminal.

[0007] According to another embodiment, a terminal arrangement structure for a high-voltage battery includes: (i) a substrate made of a first electrically insulating material and having an upper surface; (ii) a generally tubular inner wall extending from the upper surface at a first end and terminating at a second end opposite to the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius distance from the central axis of the inner wall, and an annular lip extending inward from the second end; (iii) a generally tubular outer wall extending from the upper surface at a third end and terminating at a fourth end opposite to the third end, wherein the outer wall is made of a third electrically insulating material and has an inner circumferential surface disposed at an inner radius distance from the central axis of the inner wall, and an annular lip extending inward from the second end; and (iii) a generally tubular outer wall extending from the upper surface at a third end and terminating at a fourth end opposite to the third end, wherein the outer wall is made of a third electrically insulating material and has an inner circumferential surface disposed at an inner radius distance from the central axis of the inner wall. (iv) A conductive annular terminal disposed on top of the upper surface and surrounding the inner wall between the inner wall and the outer wall; (v) a conductive tubular terminal extending through an aperture formed in the upper surface of the substrate and having an outer circumferential surface configured to contact the inner circumferential surface of the inner wall; (vi) a dielectric layer covering the substrate and having a window formed therein, through which corresponding portions of the inner wall, the outer wall and the tubular terminal protrude; and (vii) an electrical line carried by the substrate and operatively connected to at least one of the annular terminal and the tubular terminal.

[0008] In this embodiment, the outer wall is attached to the substrate in the following ways: (a) the substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions snap into corresponding grooves in the first plurality of grooves; or (b) the outer wall is molded as part of the substrate. Similarly, in this embodiment, the inner wall is attached to the substrate in at least one of the following ways: (c) the substrate has a third plurality of grooves formed in the upper surface, and the inner wall has a fourth plurality of protrusions extending radially outward from the first end, wherein the fourth plurality of protrusions snap into corresponding grooves in the third plurality of grooves; (d) the inner wall is press-fitted to the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on the outer circumferential surface that are wider than the orifice to prevent the lower portion of the tubular terminal from passing through the orifice; and (e) the inner wall is molded as part of the substrate.

[0009] Similarly, in this embodiment, the first plurality of grooves, the second plurality of protrusions, the third plurality of grooves, and the fourth plurality of protrusions may each be arranged circumferentially around the central axis. Furthermore, the inner wall may be molded as part of the substrate and may cover at least a portion of the tubular terminal, and the outer wall may be molded as part of the substrate, and the outer wall may include a plurality of outer wall segments arranged circumferentially around the central axis.

[0010] The inner wall and the outer wall may have corresponding inner and outer heights above the top surface of the annular terminal, and the annular terminal may have a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span dimensions are set to prevent fingertips of a person exceeding a predetermined size from contacting the annular terminal. Additionally, the annular lip may have an annular lip thickness and may define an annular hole with an annular hole diameter, wherein the annular hole diameter and the annular lip thickness dimensions are set to prevent fingertips of a person exceeding a predetermined size from contacting the tubular terminal. Furthermore, the second and third electrical insulating materials may be the same.

[0011] According to yet another embodiment, a terminal arrangement structure for a high-voltage battery includes: a substrate made of a first electrically insulating material and having an upper surface; a tubular inner wall extending from the upper surface at a first end and terminating at a second end opposite to the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius away from the central axis of the inner wall, and an annular lip extending inward from the second end; a tubular outer wall extending from the upper surface at a third end and terminating at a fourth end opposite to the third end, wherein the outer wall is made of a third electrically insulating material and has an outer radius extending from the central axis greater than the inner radius, wherein the outer wall is concentric with the inner wall; a conductive annular terminal disposed on top of the upper surface and surrounding the inner wall between the inner wall and the outer wall; and a conductive tubular terminal extending through an aperture formed in the upper surface of the substrate and having an outer circumferential surface disposed to contact the inner circumferential surface of the inner wall.

[0012] The outer wall is attached to the substrate in such a way that the substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions snap into corresponding grooves in the first plurality of grooves. The inner wall is attached to the substrate in such a way that the inner wall is press-fitted to the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on the outer circumferential surface that are wider than the orifice, so as to prevent the lower portion of the tubular terminal from passing through the orifice.

[0013] In this configuration, the inner wall and the outer wall may have corresponding inner and outer heights above the top surface of the annular terminal, and the annular terminal may have a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span dimensions are set to prevent fingertips of a person exceeding a predetermined size from touching the annular terminal. The terminal arrangement may also include a dielectric layer covering the substrate and having windows formed therein, through which corresponding portions of the inner wall, the outer wall, and the tubular terminal protrude. The configuration may also include electrical wiring carried by the substrate and operatively connected to at least one of the annular terminal and the tubular terminal.

[0014] The present invention also includes the following technical solutions.

[0015] Option 1. A terminal arrangement structure, comprising: The substrate is made of a first electrically insulating material and has an upper surface; A generally tubular inner wall, which extends from the upper surface at its first end and terminates at its second end opposite the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius away from the central axis of the inner wall, and an annular lip extending inward from the second end; A generally tubular outer wall, which extends from the upper surface at its third end and terminates at its fourth end opposite the third end, wherein the outer wall is made of a third electrically insulating material and has an outer radius greater than the inner radius extending from the central axis, wherein the outer wall is concentric with the inner wall; A conductive ring terminal is disposed on top of the upper surface and surrounds the inner wall between the inner wall and the outer wall; and A conductive tubular terminal extends through an aperture formed in the upper surface of the substrate and has an outer circumferential surface configured to contact the inner circumferential surface of the inner wall. The outer wall is attached to the substrate in the following manner: The substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions snap into corresponding grooves in the first plurality of grooves, or The outer wall is molded as part of the substrate; and The inner wall is attached to the substrate in at least one of the following ways: The substrate has a third plurality of grooves formed in the upper surface, and the inner wall has a fourth plurality of protrusions extending radially outward from the first end, wherein the fourth plurality of protrusions engage with corresponding grooves in the third plurality of grooves. The inner wall is press-fitted onto the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on its outer circumferential surface that are wider than the orifice, to prevent the lower portion of the tubular terminal from passing through the orifice. The inner wall is molded as part of the substrate.

[0016] Option 2. According to the terminal arrangement structure described in Option 1, wherein the first plurality of slots, the second plurality of protrusions, the third plurality of slots and the fourth plurality of protrusions are each arranged circumferentially around the central axis.

[0017] Option 3. The terminal arrangement structure according to Option 1, wherein the inner wall is molded as part of the substrate and covers at least a portion of the tubular terminal.

[0018] Option 4. The terminal arrangement structure according to Option 1, wherein the outer wall is molded as part of the substrate, and the outer wall includes a plurality of outer wall segments arranged circumferentially around the central axis.

[0019] Option 5. The terminal arrangement structure according to Option 1, wherein the inner wall and the outer wall have corresponding inner height and outer height above the top surface of the annular terminal, and the annular terminal has a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span are set to prevent fingertips of a person exceeding a predetermined size from touching the annular terminal.

[0020] Option 6. The terminal arrangement structure according to Option 1, wherein the annular lip has an annular lip thickness and defines an annular hole with an annular hole diameter, wherein the annular hole diameter and the annular lip thickness are set to prevent fingertips of a person exceeding a predetermined size from contacting the tubular terminal.

[0021] Option 7. The terminal arrangement structure according to Option 1, wherein the second electrical insulating material and the third electrical insulating material are the same.

[0022] Option 8. The terminal arrangement structure according to Option 1, wherein the first electrical insulating material, the second electrical insulating material, and the third electrical insulating material are the same.

[0023] Option 9. The terminal arrangement structure according to Option 1 further includes: A dielectric layer covering the substrate and having a window formed therein, through which corresponding portions of the inner wall, the outer wall, and the tubular terminal protrude.

[0024] Option 10. The terminal arrangement structure according to Option 1 further includes: An electrical circuit, carried by the substrate, and operatively connected to at least one of the annular terminal and the tubular terminal.

[0025] Option 11. A terminal arrangement structure for a high-voltage battery, comprising: The substrate is made of a first electrically insulating material and has an upper surface; A generally tubular inner wall, which extends from the upper surface at its first end and terminates at its second end opposite the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius away from the central axis of the inner wall, and an annular lip extending inward from the second end; A generally tubular outer wall, which extends from the upper surface at its third end and terminates at its fourth end opposite the third end, wherein the outer wall is made of a third electrically insulating material and has an outer radius greater than the inner radius extending from the central axis, wherein the outer wall is concentric with the inner wall; A conductive ring terminal is disposed on top of the upper surface and surrounds the inner wall between the inner wall and the outer wall; A conductive tubular terminal extends through an aperture formed in the upper surface of the substrate and has an outer circumferential surface configured to contact the inner circumferential surface of the inner wall. A dielectric layer covering the substrate and having a window formed therein, with corresponding portions of the inner wall, the outer wall, and the tubular terminal protruding through the window; and An electrical circuit, carried by the substrate and operatively connected to at least one of the annular terminal and the tubular terminal; The outer wall is attached to the substrate in the following manner: The substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions snap into corresponding grooves in the first plurality of grooves, or The outer wall is molded as part of the substrate; and The inner wall is attached to the substrate in at least one of the following ways: The substrate has a third plurality of grooves formed in the upper surface, and the inner wall has a fourth plurality of protrusions extending radially outward from the first end, wherein the fourth plurality of protrusions engage with corresponding grooves in the third plurality of grooves. The inner wall is press-fitted onto the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on its outer circumferential surface that are wider than the orifice, to prevent the lower portion of the tubular terminal from passing through the orifice. The inner wall is molded as part of the substrate; The first plurality of grooves, the second plurality of protrusions, the third plurality of grooves, and the fourth plurality of protrusions are each arranged circumferentially around the central axis.

[0026] Option 12. The terminal arrangement structure according to Option 11, wherein the inner wall is molded as part of the substrate and covers at least a portion of the tubular terminal.

[0027] Option 13. The terminal arrangement structure according to Option 11, wherein the outer wall is molded as part of the substrate, and the outer wall includes a plurality of outer wall segments arranged circumferentially around the central axis.

[0028] Option 14. The terminal arrangement structure according to Option 11, wherein the inner wall and the outer wall have corresponding inner height and outer height above the top surface of the annular terminal, and the annular terminal has a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span are set to prevent fingertips of a person exceeding a predetermined size from touching the annular terminal.

[0029] Option 15. The terminal arrangement structure according to Option 11, wherein the annular lip has an annular lip thickness and defines an annular hole with an annular hole diameter, wherein the annular hole diameter and the annular lip thickness are configured to prevent fingertips of a person exceeding a predetermined size from contacting the tubular terminal.

[0030] Option 16. The terminal arrangement structure according to Option 11, wherein the second electrical insulating material and the third electrical insulating material are the same.

[0031] Option 17. A terminal arrangement structure for a high-voltage battery, comprising: The substrate is made of a first electrically insulating material and has an upper surface; A tubular inner wall extending from the upper surface at its first end and terminating at its second end opposite to the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius away from the central axis of the inner wall, and an annular lip extending inward from the second end; A tubular outer wall, which extends from the upper surface at its third end and terminates at its fourth end opposite to the third end, wherein the outer wall is made of a third electrically insulating material and has an outer radius greater than the inner radius extending from the central axis, wherein the outer wall is concentric with the inner wall; A conductive ring terminal is disposed on top of the upper surface and surrounds the inner wall between the inner wall and the outer wall; and A conductive tubular terminal extends through an aperture formed in the upper surface of the substrate and has an outer circumferential surface configured to contact the inner circumferential surface of the inner wall. The outer wall is attached to the substrate in the following manner: the substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions engage with corresponding grooves in the first plurality of grooves; and The inner wall is attached to the substrate by press-fitting the inner wall to the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on the outer circumferential surface that are wider than the orifice to prevent the lower portion of the tubular terminal from passing through the orifice.

[0032] Option 18. The terminal arrangement structure according to Option 17, wherein the inner wall and the outer wall have corresponding inner height and outer height above the top surface of the annular terminal, and the annular terminal has a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span are configured to prevent fingertips of a person exceeding a predetermined size from touching the annular terminal.

[0033] Option 19. The terminal arrangement structure according to Option 17 further includes: A dielectric layer covering the substrate and having a window formed therein, through which corresponding portions of the inner wall, the outer wall, and the tubular terminal protrude.

[0034] Option 20. The terminal arrangement structure according to Option 19 further includes: An electrical circuit, carried by the substrate, and operatively connected to at least one of the annular terminal and the tubular terminal.

[0035] The foregoing features and advantages, as well as other features and advantages, of this teaching will be apparent when taken in conjunction with the accompanying drawings, based on the following detailed description of some of the best modes and other embodiments for carrying out this teaching as defined in the appended claims. Attached Figure Description

[0036] Figure 1 This is a schematic perspective view of the anti-finger terminal arrangement structure according to the present disclosure.

[0037] Figure 2 This is a schematic plan view of the terminal arrangement structure.

[0038] Figure 3 This is a schematic cross-sectional view of a substrate and annular terminals according to one embodiment of the terminal arrangement structure.

[0039] Figure 4 yes Figure 3 A schematic cross-sectional view of the components, with added tubular terminals (e.g., clinchnuts).

[0040] Figure 5 yes Figure 4 A schematic cross-sectional view of the component, with the inner walls added.

[0041] Figure 6 yes Figure 5 A schematic cross-sectional view of the components, with an outer wall added, thus completing an embodiment of the terminal arrangement structure.

[0042] Figure 7 yes Figure 6 A schematic cross-sectional view of an embodiment, in which a matching busbar has been added.

[0043] Figure 8-12 This is a schematic cross-sectional view of another embodiment of the terminal arrangement structure.

[0044] Figure 13 This is a schematic plan view of another embodiment of the terminal arrangement structure, wherein the outer wall includes multiple segments.

[0045] Figure 14 It is a block diagram illustrating various structures for attaching the inner and outer walls to the substrate. Detailed Implementation

[0046] Referring now to the accompanying drawings, wherein like reference numerals denote like parts in several views, various embodiments of the finger-resistant terminal arrangement 20 according to the present disclosure are shown and described herein. These various embodiments of the terminal arrangement 20 can be used in high-voltage applications, such as for the positive and negative terminals of batteries in electric and hybrid electric vehicle vehicles, and can be designed and configured to make the terminal arrangement 20 finger-resistant, as described in more detail below.

[0047] Figure 1-2 Correspondingly, schematic perspective and plan views of one embodiment of the anti-finger terminal arrangement structure 20 are shown, while Figure 3-6 The illustration shows the sequential steps for assembling this embodiment. The terminal arrangement structure 20 includes a substrate 22 made of a first electrically insulating material M1 and having an upper surface 25. Note that around... Figure 1-2 Each of the long dashed rectangles in the diagram represents a portion of the entire substrate 22, while Figure 1-2 The short dashed lines in the diagram represent the first and second electrical lines 81, 82 extending below the upper surface 25 of the substrate 22. The terminal arrangement structure 20 also includes a generally tubular inner wall or ring 30 and a generally tubular outer wall or ring 40, wherein the inner and outer walls 30, 40 are attached to the substrate 22 by one of a variety of attachment structures 99, as described below. Depending on the attachment structure 99 used, the substrate 22 may include grooves 28 formed therein for attaching the outer wall 40 to the substrate 22, and / or grooves 24 formed therein for attaching the inner wall 30 to the substrate 22, of a third variety 23. Note that although... Figure 2 Only two slots 28 are shown, but any number of slots 28 (and any number of slots 24) can be set.

[0048] A generally tubular inner wall or ring 30 extends upward from the upper surface 25 of the substrate 22 from a first end or lower end 31 of the inner wall 30, wherein the inner wall 30 terminates at a second end or upper end 32 opposite to the first end 31. The inner wall 30 is made of a second electrically insulating material M2 and has an inner wall height H measured from the upper surface 25. i It also has an inner circumferential surface 33, which is provided with an inner radius R from the central axis 34 of the inner wall 30. i and the outer diameter of the inner wall D 30 The inner wall 30 also has an annular lip 35, which extends inward from the second end or the upper end 32, and has an annular lip thickness or height T. 35 (Measured along the central axis 34) and the length L of the annular lip 35 (Measured radially from the inner circumference to surface 33). For example... Figure 5 As shown, the annular lip 35 defines a hole with an annular diameter D. 36 36. Annular hole.

[0049] As shown in the accompanying drawings and further described in detail below, note that the inner wall 30, as well as the outer wall 40, the annular terminal 50, and the tubular terminal 60, may have generally circular or annular profiles. These profiles are concentric with each other when viewed from above in a plan view, wherein a central axis 34 extends through the center of these profiles and defines the axis of rotation for the three-dimensional volumetric shape of these elements 30, 40, 50, and 60. Furthermore, as... Figure 3 As shown, the central axis 34 can define a radially inward direction d pointing towards the central axis 34. i d in the radial outward direction away from the central axis 34 o and along or parallel to the longitudinal direction d of the central axis 34 L .

[0050] A generally tubular outer wall or ring 40 also extends upward from the upper surface 25 of the substrate 22. The outer wall 40 has a third end or lower end 41 attached to or integrated with the substrate 22, and a fourth end or upper end 42 opposite to the third end 41. The outer wall 40 is made of a third electrically insulating material M3 and has an outer radius R extending from the central axis 34. o Where, outer radius R o Greater than the inner radius R i (that is, R) o > R i For example, inner radius R i It can extend to the outer circumferential surface of the inner wall 30, and the outer radius R o It can extend to the inner circumferential surface of the outer wall 40, thereby providing a radial span or gap 54 between the inner wall 30 and the outer wall 40. The outer wall 40 has an outer wall height H measured from the upper surface 25. o It can be optionally matched with the inner wall height H i Same. As described above, the outer wall 40 is oriented and arranged concentrically with the inner wall 30. The outer wall 40 may take the form of a single wall or ring, or it may take the form of multiple segments 46 having a generally tubular shape or arrangement together (e.g., Figure 13 (as shown in the diagram and discussed below).

[0051] A conductive annular terminal 50 is disposed on top of the upper surface 25 and surrounds the inner wall 30 between the inner wall 30 and the outer wall 40. Furthermore, a conductive tubular terminal 60 (e.g., a fastening nut) extends through an aperture or gap 26 formed in the upper surface 25 of the substrate 22, wherein the tubular terminal 60 has an outer circumferential surface 62 configured to physically contact the inner circumferential surface 33 of the inner wall 30. Note that the annular terminal 50 may have the shape of a flat washer having a longitudinal direction d. L The measured relatively small height or thickness, while the inner wall 30, outer wall 40, and tubular terminal 60 each have a longitudinal direction d LThe corresponding heights are measured, and these heights are much greater than the height or thickness of the annular terminal 50. Both the annular terminal 50 and the tubular terminal 60 are made of a conductive material, such as copper, steel, or aluminum.

[0052] As mentioned above, Figure 3-6 The illustration shows the sequential steps for assembling the terminal arrangement structure 20 in one embodiment. This series of assembly steps will now be explained step by step.

[0053] First, such as Figure 3 As shown, a substrate 22 is provided, wherein the substrate 22 has an aperture 26 formed on its upper surface 25 therein, and a pocket or gap 29 formed on the underside of the substrate 22 opposite to or below the aperture 26. The aperture 26 may be defined by a circumferential wall or edge 21 extending downward from the upper surface 25, wherein the circumferential wall / edge 21 is concentric with and defines a central axis 34. The substrate 22 includes an annular terminal 50, the top surface 52 of which may be continuous with or coplanar with the upper surface 25, or may be positioned slightly above or below the upper surface 25. The substrate 22 may also contain or carry first and second electrical lines 81, 82, which are electrically connected to or can be electrically connected to each other, as further described below. (Alternatively, only one of such lines 81, 82 may be provided, so that the two lines 81, 82 shown can be used as two segments of a single electrical line.) Note that for illustrative purposes, Figure 3 It also includes an optional dielectric layer 70 having a window 72, but this dielectric layer 70 is not included in Figure 4-6 Additionally, the substrate 22 may include trenches 28 formed therein (e.g., in and / or through the upper surface 25). Each trench 28 may include an opening 28 in the upper surface 25 (and / or the dielectric layer 70). c , at the opening 28 c The main chamber below 28 m And in the main chamber 28 m Next to and towards the main chamber 28 m Open side chamber 28 s Side chamber 28 s Located from opening 28 c Radial outward positioning of the top or protrusion 28 o Below. If necessary, the substrate 22 constitutes the top or protrusion 28. o Parts of the substrate 22 (and any other parts of the substrate 22 that contribute to the formation of the groove 28) may be made of a different material than the rest of the substrate 22.

[0054] Secondly, such as Figure 4As shown, the tubular terminal 60 is inserted into the cavity 29 on the lower side of the substrate 22, such that the upper portion 64 of the tubular terminal 60 extends above the upper surface 25 of the substrate 22 by a height H. t The lower portion 66 remains below the upper surface 25 and within the cavity 29. The tubular terminal 60 may be sized to have: a first or main shoulder 68 of an exposed portion 84 that contacts the second electrical line 82; and an upper portion 64 that is fitted through the orifice 26 and has an upper portion diameter D. 64 ; and the lower portion 66, which is fitted into the cavity 29 and has a lower portion diameter D that prevents the lower portion 66 from being fitted through the orifice 26. 66 The tubular terminal 60 may optionally have a second shoulder 61 on the outer circumferential surface 62 and an intermediate portion 63 between the upper and lower portions 64, 66. Optionally, the upper and lower portions have a diameter D. 64 D 66 The orifice 26 and the cavity 29 can be sized to provide a tight fit between the upper portion 64 and the orifice 26, and between the lower portion 66 and the inside of the cavity 29. The cylindrical hole 65 is located along the longitudinal direction d. L (Concentric with the central axis 34) Extends through the tubular terminal 60 and is defined by an inner cylindrical surface 67, which may be threaded to mate with threaded fasteners.

[0055] Third, such as Figure 5 As shown, the inner wall 30 is press-fitted onto the upper portion 64 of the tubular terminal 60, such that an interference fit is provided between the inner circumferential surface 33 of the inner wall 30 and the outer circumferential surface 62 of the tubular terminal 60. This press-fit or interference fit keeps the inner wall 30 and the tubular terminal 60 in contact with each other and can also be used to clamp the inner wall 30 tightly onto the upper surface 25 of the substrate 22 and the tubular terminal 60 abutting a portion of the cavity 29 on the underside of the substrate 22. (Note that if an optional dielectric layer 70 is used, the inner wall 30 can be clamped tightly against the dielectric layer 70 or against the upper surface 25 of the substrate 22, depending on whether the dielectric layer 70 extends below the inner wall 30.)

[0056] Fourth, such as Figure 6 As shown, the outer wall 40 is snapped onto the base plate 22 by bending the protrusions 44 of the second plurality of 43 inward (i.e., toward the central axis 34) and inserting / snap them into the slots 28 of the first plurality of 27, such that the protrusions 44 rest in the side chamber 28. s Inside, and located at the top / protrusion 28 of the outside of the groove 28. o Below and captured by it. Like here... Figure 6As shown, when the substrate 22, the annular terminal 50, the tubular terminal 60, the inner wall 30 and the outer wall 40 are arranged and combined as described, the resulting combination provides an embodiment of the terminal arrangement structure 20.

[0057] However, please note that these four steps can be performed in a different order than described above. For example, the outer wall 40 can be snapped onto the substrate 22 before the inner wall 30 and the tubular terminal 60 are attached to the substrate 22. Also note that although the figures show the protrusions 38, 44 slightly spaced from the sides of their respective grooves 24, 28, this is merely for illustrative purposes, as the protrusions 38, 44 may contact or abut against one or more sides or boundaries of their respective grooves 24, 28.

[0058] As shown differently in the accompanying drawings, and as... Figure 14 As specifically illustrated in the block diagram, there are various attachment structures 99, in which the inner and outer walls 30, 40 can be attached to or integrally formed with the substrate 22. Each of these attachment structures 99 can be represented by two reference characters: an initial letter character, namely A or B, to indicate how the outer wall 40 is attached to or integrally formed with the substrate 22, followed by a Roman numeral character, namely I, II or III, to specify how the inner wall 30 is attached to or integrally formed with the substrate 22.

[0059] The letter "A" indicates that the outer wall 40 is attached to the substrate 22 in such a manner that the substrate 22 has a first plurality of grooves 28 of 27 formed in the upper surface 25 of the substrate 22, and the outer wall 40 has a second plurality of protrusions 44 of 43 extending radially outward from the third end or lower end 41, wherein the grooves 28 of the first plurality of 27 and the protrusions 44 of the second plurality of 43 are arranged and sized such that the protrusions 44 of the second plurality of 43 can snap into corresponding grooves in the grooves 28 of the first plurality of 27. This "A" configuration in Figure 1-8 and Figure 12 As shown in the diagram. Alternatively, the letter "B" indicates that the outer wall 40 is molded as part of the substrate 22, as shown in the diagram. Figure 9-11 and Figure 13 As shown in the diagram. Note that, as used herein, “molding” means molding, shaping, or forming, such as by injection molding or some other molding or forming process, including additive manufacturing.

[0060] The Roman numeral "I" indicates that the inner wall 30 can be attached to the substrate 22 in the following manner: the substrate 22 has a third plurality of grooves 24 of 23 formed in the upper surface 25, and the inner wall 40 has a fourth plurality of protrusions 38 of 37 extending radially outward from the first end 31, wherein the grooves 24 of the third plurality of 23 and the protrusions 38 of the fourth plurality of 37 are arranged and sized such that the protrusions 38 of the fourth plurality of 37 can snap into corresponding grooves in the grooves 24 of the third plurality of 23, such as... Figure 11-12 As shown in the diagram. Alternatively, the Roman numeral "II" indicates that the inner wall 30 can be press-fitted onto the upper portion 64 of the tubular terminal 60, wherein the tubular terminal 60 has one or more shoulders 68 on its outer circumferential surface 62, which are wider than the aperture 26 in the upper surface 25 of the substrate 22 to prevent the lower portion 66 of the tubular terminal 60 from passing through the aperture 26, as shown in the diagram. Figure 6-7 and Figure 9 As shown in the diagram. (Note that this configuration can also be viewed as the upper portion 64 of the tubular terminal 60 being press-fitted into the inner wall 30, or the upper portion 64 of the tubular terminal 60 and the inner wall 30 being press-fitted together relative to each other. Regardless of the viewpoint, part or all of the outer circumferential surface 62 of the tubular terminal 60 is configured to physically contact part or all of the inner circumferential surface 33 of the inner wall 30.) In this configuration, the upper portion 64 of the tubular terminal 60 has an upper portion diameter D. 64 Furthermore, the lower portion 66 has a larger diameter D than the upper portion. 64 The lower part has a diameter D 66 (that is, D) 66 > D 64 In addition to the upper portion 64 of the tubular terminal 60 being press-fitted into the inner wall 30, the upper portion 64 may also be press-fitted into the orifice 26. (That is, the outer peripheral surface 62 of the tubular terminal 60 may be configured to physically contact the outer rim or circumferential wall / edge 21 of the orifice 26. More specifically, the portion of the outer peripheral surface 62 that physically contacts the outer rim 21 of the orifice 26 may be the portion of the outer peripheral surface 62 surrounding the upper portion 64 of the tubular terminal 60. And as an alternative, the Roman numeral "III" indicates that the inner wall 30 may be molded as part of the substrate 22 (e.g., by injection molding or some other molding or forming process), such as Figure 8 and Figure 10 As shown in the image.

[0061] therefore, Figure 1-7The embodiment shown can be considered as an “A-II” construction, wherein the outer wall 40 is attached to the substrate 22 in such a way that the substrate 22 has grooves 28 of a first plurality of 27 formed in the upper surface 25, and the outer wall 40 has protrusions 44 of a second plurality of 43 extending radially outward from the third end 41, wherein the protrusions 44 of the second plurality of 43 are snap-fitted into corresponding grooves in the grooves 28 of the first plurality of 27 (therefore, part “A” of the construction). Additionally, the inner wall 30 is attached to the substrate 22 in such a way that the inner wall 30 is press-fitted to the upper portion 64 of the tubular terminal 60, and the tubular terminal 60 has one or more shoulders 61, 68 on its outer peripheral surface 62 that are wider than the opening 26 in the substrate 22, in order to prevent the lower portion 66 of the tubular terminal 60 from passing through the opening 26 (therefore, part “II” of the construction).

[0062] Generally, the outer wall 40 can be attached to the substrate 22 in such a way that the substrate 22 has grooves 28 of a first plurality of 27 formed in the upper surface 25, and the outer wall 40 has protrusions 44 of a second plurality of 43 extending radially outward from the third end 41, wherein the protrusions 44 of the second plurality of 43 are snap-fitted into corresponding grooves in the grooves 28 of the first plurality of 27 (construction "A"), or the outer wall 40 can be molded as part of the substrate 22 (construction "B"). Additionally, the inner wall 30 can be attached to the substrate 22 in one or more of the following ways: (i) the substrate 22 has a third plurality of grooves 24 formed in the upper surface 25, and the inner wall 30 has a fourth plurality of protrusions 38 extending radially outward from the first end 31, wherein the protrusions 38 of the fourth plurality of 37 are snap-fitted into corresponding grooves in the third plurality of 23 grooves 24 (construction "I"); (ii) the inner wall 30 is press-fitted onto the upper portion 64 of the tubular terminal 60, wherein the tubular terminal 60 has one or more shoulders 68 on the outer peripheral surface 62 that are wider than the orifice 26 to prevent the lower portion 66 of the tubular terminal 60 from passing through the orifice 26 (construction "II"); and (iii) the inner wall 30 is molded as part of the substrate 22 (construction "III"). Thus, as Figure 14 As shown, there are six different basic attachment structures 99: AI, A-II, A-III, BI, B-II, and B-III. Additionally, two or more of the I, II, and III structures can be combined together.

[0063] The first plurality of slots 28 of 27 and the second plurality of protrusions 44 of 43 (if configuration "A" is used), and / or the third plurality of slots 24 of 23 and the fourth plurality of protrusions 38 of 37 (if configuration "I" is used) may be arranged circumferentially about the central axis 34 and may be arranged concentrically relative to each other. If configuration "I" is used (e.g. Figure 11-12As shown in the diagram, the substrate 22 may include a third plurality of grooves 24 formed therein (e.g., in and / or through the upper surface 25). In this case, each groove 24 may include an opening 24 in the upper surface 25 (and / or the dielectric layer 70). c , at the opening 24 c The main chamber below 24 m And in the main chamber 24 m Next to and towards the main chamber 24 m Open side chamber 24 s Side chamber 24 s Located from opening 24 c Radial outward positioning of the top or protrusion 24 o Below. If the inner wall 30 is molded as part of the substrate 22, the inner wall 30 may cover or enclose at least a portion 69 (e.g., the upper portion 64) of the molded tubular terminal 60. For example, such covering or enclosing molding may be performed by insert molding, wherein the tubular terminal 60 is placed in the mold as an "insert" and polymer material is injected into the cavity surrounding the tubular terminal 60. In this case, as the polymer cools or solidifies, the inner wall 30 is formed to wrap around, surround, or encapsulate at least a portion 69 (e.g., the upper portion 64) of the tubular terminal 60. Furthermore, if the outer wall 40 is molded as part of the substrate 22, the outer wall 40 may include a plurality of outer wall segments 46 arranged circumferentially about the central axis 34, such as Figure 13 As shown in the image.

[0064] The inner and outer walls 30 and 40 may have corresponding inner and outer heights H above the top surface 52 of the annular terminal 50 (and / or above the upper surface 25 of the substrate 22). i H o Furthermore, the annular terminal 50 may have a radial span 54 between the inner wall 30 and the outer wall 40, wherein the inner height and the outer height H i H o The radial span 54 is sized, spaced, or otherwise configured to prevent the fingertips of one or more people, or fingertip probes 15 exceeding a predetermined size, from contacting the annular terminal 50, thereby making the terminal arrangement 20 "fingerproof". In other words, the height H of the inner and outer walls 30, 40... i H oThe radial span or spacing 54 between them can be selected to prevent a worker's finger 15 from accidentally contacting the annular terminal 50 and potentially receiving an electric shock from it. This "finger-proof" feature can be verified during the production and assembly of the terminal arrangement structure 20 using a standardized fingertip probe 15 (i.e., a finger-shaped testing device) to ensure that the probe 15 cannot contact the annular terminal 50. Note that the predetermined size of the fingertip probe 15 can be selected to simulate a specific male or female finger at a given percentile of size (e.g., the 5th percentile female index finger, the 95th percentile male index finger, etc.).

[0065] In addition to finger protection for the annular terminal 50 (or as an alternative), the tubular terminal 60 can also be finger-proof. For example, the annular lip 35 may have an annular lip thickness T. 35 (in the longitudinal direction d) L (measured above), and can be defined with an annular hole diameter D 36 (Radial measurement) Annular hole 36, wherein the diameter of the annular hole is D 36 and the thickness of the annular lip T 35 The size is set and / or arranged to prevent the fingertips (or fingertip probes) 15 of a person exceeding a predetermined size from reaching or contacting the tubular terminal 60. (That is, the annular hole 36 is too small, and / or the annular lip thickness T...) 35 If it is too thick or too high, the finger or fingertip probe 15 of a person exceeding the predetermined size will not be able to reach the tubular terminal 60.

[0066] The second and third electrical insulating materials M2 and M3 can be the same material, or the first, second, and third electrical insulating materials M1, M2, and M3 can be the same material. Exemplary candidates for these materials M1, M2, and M3 include (but are not limited to) thermoplastic polymers and thermosetting polymers. As an example, the second electrical insulating material M2 used to form the inner wall 30 can be an elastomeric material to facilitate the press-fitting of the inner wall 30 onto the tubular terminal 60, and the third electrical insulating material M3 used to form the outer wall 40 can be a relatively rigid polymer. The terminal arrangement structure 20 may also include a dielectric layer 70 that covers part or all of the substrate 22 and has a window 72 formed therein through which corresponding portions 39, 49, and 69 of the inner wall 30, outer wall 40, and tubular terminal 60 protrude. The terminal arrangement structure 20 may also include a first electrical line 81 carried by the substrate 22 and operatively connected to the annular terminal 50, and a second electrical line 82 carried by the substrate 22 and operatively connected to the tubular terminal 60. Each of these electrical lines 81, 82 may include wires, cables, layers, traces, mechanical components, etc., made of conductive materials (e.g., copper, aluminum, other metals, carbon, carbon nanotubes, graphene, etc.) and be capable of safely carrying the voltages and amperes required for the intended application (e.g., high-voltage batteries or battery modules for electric vehicles, such as up to 800 volts and up to 125 amperes). As used herein, "carried by substrate 22" means that electrical lines 81, 82 may be disposed on or attached to the outer surface or exposed surface of substrate 22, and / or electrical lines 81, 82 may be embedded within substrate 22. It should also be noted that although some figures may show two electrical lines 81, 82 that appear to be separate from each other, it should be noted that these two lines 81, 82 are electrically connected to each other, especially when all components of the terminal arrangement structure 20 are in place.

[0067] Figure 6 A schematic cross-sectional view of the substrate 22 and tubular terminals 60 is shown after the inner wall 30 and outer wall 40 have been attached to the substrate 22 to form the terminal arrangement structure 20. Figure 7 It shows the relationship with Figure 6The same view, but with a mating busbar 90 positioned for mechanical and electrical contact with terminal arrangement 20. More specifically, the mating busbar 90 includes a generally tubular wall or ring portion 94 extending from one end of a main portion 92 of the busbar 90, wherein the ring portion 94 is sized and dimensioned such that it can be inserted between inner and outer walls 30, 40 and positioned for tactile and electrical contact with annular terminal 50. Fastener holes 96 may be provided in the main portion 94 such that fasteners (e.g., bolts) can be inserted through the fastener holes 96 and into a (optionally threaded) cylindrical hole 65 of the tubular terminal 60. Although not shown in the figure, the mating busbar 90 includes electrical leads extending through the main portion 92 and the ring portion 94. Fasteners (not shown) are inserted through the fastener holes 96 and secured (e.g., by thread) to bring the ring portion 94 into mechanical and electrical contact with annular terminal 50.

[0068] Note that in Figure 6-7 In this configuration, the terminal arrangement structure 20 can be considered as being in the "A-II" configuration. Regarding... Figure 3-4 Since the inner and outer walls 30 and 40 have not yet been attached, the terminal arrangement structure 20 has not yet been formed. However, once the inner wall 30 is attached (e.g., Figure 5 As shown in the diagram), then the "II" construction will be complete, and once the outer wall 40 has been attached (as shown in the diagram), the construction will be finished. Figure 6 As shown in the figure, construction “A” will also be completed, thus providing a terminal arrangement structure 20 in the form of “A-II”.

[0069] Figure 8 A schematic cross-sectional view of another embodiment of the terminal arrangement structure 20 is shown, wherein this embodiment has an “A-III” configuration, and the inner wall 30 is integrally formed with the substrate 22. In contrast, Figure 9 A schematic cross-sectional view of another embodiment of the terminal arrangement structure 20 is shown, wherein this embodiment has a "B-II" configuration. Here, the outer wall 40 is integrally formed with the substrate 22, and the inner wall 30 is press-fitted to the upper portion 64 of the tubular terminal 60. Figure 10 A schematic cross-sectional view of another embodiment with a “B-III” configuration is shown, wherein both the inner wall 30 and the outer wall 40 are integrally formed with the substrate 22. Note that... Figure 8-10 A distal portion of a human finger or a finger probe 15 of a predetermined size is shown, preventing the distal portion or finger probe 15 from contacting the annular terminal 50 or the tubular terminal 60. Furthermore, Figure 11 An embodiment with a "BI" configuration is shown, wherein the outer wall 40 is integrally formed with the substrate 22, and the inner wall 30 has a slot 24 of the third plurality of slots 23 that snaps into the slots 38 of the fourth plurality of slots 37, while Figure 12An embodiment with an "AI" configuration is shown, wherein both the inner and outer walls 30, 40 have corresponding protrusions 38, 44 that are snap-fitted into corresponding grooves 28, 24. Figure 11-12 In the BI and AI embodiments, it may be advantageous to attach the inner wall 30 to the substrate 22 before inserting the tubular terminal 60 and attaching the outer wall 40. Figure 13 A schematic plan view of the “B-II” configuration is shown, in which the outer wall 40 is composed of several individual segments 46, all of which are integrally formed with the substrate 22, and the inner wall 30 is press-fitted onto the tubular terminal 60. Note that the dashed circle 17 represents the largest circle that can be fitted between two adjacent segments 46 and the inner wall 30, representing the maximum extent to which a human finger or a finger probe 15 of a predetermined size can penetrate toward the annular terminal 50 between the two segments 46 and the inner wall 30. Furthermore, although not shown in the figure, the segments 46 are also sized, spaced, and arranged to prevent a human finger or a finger probe 15 of a predetermined size from contacting the annular terminal 50 by radial insertion (between adjacent segments 46).

[0070] It can be noted that, Figure 1-2 and Figure 8 In the top plan view shown in each figure, it is not obvious which specific attachment structure 99 is used to attach or integrate the inner and outer walls 30, 40 to the substrate 22. However, Figure 2 Two grooves 28 are indeed shown in the upper surface 25 of the substrate 22 for two protrusions 44 (not shown) that mate with the grooves 28 for attaching the outer wall 40 to the substrate 22. Therefore, it is clear that at least “A” configuration is used for the terminal arrangement structure 20.

[0071] According to another embodiment, the terminal arrangement structure 20 for a high-voltage battery includes: (i) a substrate 22 made of a first electrically insulating material M1 and having an upper surface 25; and (ii) a generally tubular inner wall 30 extending from the upper surface 25 at its first end 31 and terminating at its second end 32 opposite to the first end 31, wherein the inner wall 30 is made of a second electrically insulating material M2 and has an inner radius R disposed at a distance from the central axis 34 of the inner wall 30. i (iii) An inner circumferential surface 33, and an annular lip 35 extending inward from the second end 32; (iii) a generally tubular outer wall 40 extending from the upper surface 25 at its third end 41 and terminating at its fourth end 42 opposite the third end 41, wherein the outer wall 40 is made of a third electrically insulating material M3 and has a radius greater than the inner radius R. i and the outer radius R extending from the central axis 34 o(iv) A conductive annular terminal 50 disposed on top of the upper surface 25 and surrounding the inner wall 30 between the inner wall 30 and the outer wall 40; (v) A conductive tubular terminal 60 extending through an aperture 26 formed in the upper surface 25 of the substrate 22 and having an outer circumferential surface 62 configured to contact the inner circumferential surface 33 of the inner wall 30; (vi) A dielectric layer 70 covering the substrate 22 and having a window 72 formed therein through which corresponding portions 39, 49, 69 of the inner wall 30, the outer wall 40 and the tubular terminal 60 protrude; and (vii) one or more electrical lines, such as first and second electrical lines 81, 82, which are carried by the substrate 22 and operatively connected to the annular terminal 50 and the tubular terminal 60.

[0072] In this embodiment, the outer wall 40 is attached to the substrate 22 in such a way that: (a) the substrate 22 has grooves 28 of a first plurality of 27 formed in the upper surface 25, and the outer wall 40 has protrusions 44 of a second plurality of 43 extending radially outward from the third end 41, wherein the protrusions 44 of the second plurality of 43 snap into corresponding grooves in the grooves 28 of the first plurality of 27, or (b) the outer wall 40 is molded as part of the substrate 22. In the same embodiment, the inner wall 30 is attached to the substrate 22 in the following ways: (c) the substrate 22 has a third plurality of grooves 24 formed in the upper surface 25, wherein the inner wall 30 has a fourth plurality of protrusions 38 extending radially outward from the first end 31, wherein the protrusions 38 of the fourth plurality of 37 snap into corresponding grooves in the third plurality of grooves 24; or (d) the inner wall 30 is press-fitted onto the upper portion 64 of the tubular terminal 60, and the tubular terminal 60 has one or more shoulders 68 on the outer peripheral surface 62, the shoulders 68 being wider than the orifice 26 to prevent the lower portion 66 of the tubular terminal 60 from passing through the orifice 26; or (e) the inner wall 30 is molded as part of the substrate 22.

[0073] Similarly, in this embodiment, the grooves 28 of the first plurality of 27, the protrusions 44 of the second plurality of 43, the grooves 24 of the third plurality of 23, and the protrusions 38 of the fourth plurality of 37 may each be arranged circumferentially around the central axis 34. Furthermore, the inner wall 30 may be molded as part of the substrate 22 and may cover or enclose at least a portion 69 of the molded tubular terminal 60, and the outer wall 40 may be molded as part of the substrate 22, and the outer wall 40 may include a plurality of outer wall segments 46 arranged circumferentially around the central axis 34.

[0074] The inner and outer walls 30 and 40 may have corresponding inner and outer heights H above the top surface 52 of the annular terminal 50. i H oFurthermore, the annular terminal 50 may have a radial span 54 between the inner wall 30 and the outer wall 40, wherein the inner height and the outer height H i H o The radial span 54 is sized to prevent fingertips 15 of a person exceeding a predetermined size from contacting the annular terminal 50. Additionally, the annular lip 35 may have an annular lip thickness T. 35 And it can be defined that it has an annular hole diameter D. 36 The annular hole 36, wherein the diameter of the annular hole is D 36 and the thickness of the annular lip T 35 The size is set to prevent the fingertips 15 of a person larger than a predetermined size from contacting the tubular terminal 60. Furthermore, the second and third electrical insulation materials M2 and M3 can be the same.

[0075] According to another embodiment, the terminal arrangement structure 20 for a high-voltage battery includes: a substrate 22 made of a first electrically insulating material M1 and having an upper surface 25; and a tubular inner wall 30 extending from the upper surface 25 at its first end 31 and terminating at its second end 32 opposite to the first end 31, wherein the inner wall 30 is made of a second electrically insulating material M2 and has an inner radius R disposed at a distance from the central axis 34 of the inner wall 30. i The inner circumferential surface 33, and an annular lip 35 extending inward from the second end 32; a tubular outer wall 40 extending from the upper surface 25 at its third end 41 and terminating at its fourth end 42 opposite to the third end 41, wherein the outer wall 40 is made of a third electrically insulating material M3 and has a radius greater than the inner radius R. i The outer radius R extending from the central axis 34 o The outer wall 40 is concentric with the inner wall 30; a conductive annular terminal 50 is disposed on top of the upper surface 25 and surrounds the inner wall 30 between the inner wall 30 and the outer wall 40; and a conductive tubular terminal 60 extends through an aperture 26 formed in the upper surface 25 of the substrate 22 and has an outer circumferential surface 62 configured to contact the inner circumferential surface 33 of the inner wall 30.

[0076] The outer wall 40 is attached to the substrate 22 in such a way that the substrate 22 has a first plurality of grooves 28 formed in the upper surface 25, and the outer wall 40 has a second plurality of protrusions 44 extending radially outward from the third end 41, wherein the protrusions 44 of the second plurality of 43 snap into corresponding grooves in the first plurality of 27 grooves 28. The inner wall 30 is attached to the substrate 22 in such a way that the inner wall 30 is press-fitted to the upper portion 64 of the tubular terminal 60, and the tubular terminal 60 has one or more shoulders 68 on the outer peripheral surface 62 that are wider than the orifice 26 in order to prevent the lower portion 66 of the tubular terminal 60 from passing through the orifice 26.

[0077] In this configuration, the inner and outer walls 30 and 40 may have corresponding inner and outer heights H above the top surface 52 of the annular terminal 50. i H o Furthermore, the annular terminal 50 may have a radial span 54 between the inner wall 30 and the outer wall 40, wherein the inner height and the outer height H i H o The radial span 54 is sized to prevent fingertips 15 of a person exceeding a predetermined size from contacting the annular terminal 50. The terminal arrangement structure 20 may also include a dielectric layer 70 covering the substrate 22 and having a window 72 formed therein, through which corresponding portions 39, 49, 69 of the inner wall 30, outer wall 40, and tubular terminal 60 protrude. This configuration may also include one or more electrical lines, such as first and second electrical lines 81, 82, which are carried by the substrate 22 and operatively connected to the annular terminal 50 and the tubular terminal 60.

[0078] In each of the above configurations and embodiments, electrical power (e.g., high-voltage power) may be transmitted along electrical lines (e.g., lines 81 and / or 82) carried by the substrate 22, then through the annular terminal 50 and / or the tubular terminal 60, and subsequently through the tubular wall / annular portion 94 (and optionally also through a fastener extending through the fastener hole 96 and connected to the tubular terminal 60) into the busbar 90. Alternatively, the electrical power may travel in the opposite direction.

[0079] The above description is intended to be illustrative and not restrictive. While the dimensions and types of materials described herein are intended to be illustrative, they are by no means restrictive and are exemplary embodiments. In the following claims, the terms “first,” “second,” “top,” “bottom,” “upper,” “lower,” “inner,” “outer,” etc., are used merely as labels and are not intended to impose numerical or positional requirements on the objects thereto, unless required by context or logic. As used herein, elements or steps recited in the singular and those beginning with the terms “a,” “an,” or “an” should be understood to not exclude a plurality of such elements or steps, unless such exclusion is expressly stated. Furthermore, the phrases “at least one of A and B” and “A and / or B” should each be understood to mean “only A, only B, or both A and B.” Furthermore, unless explicitly stated to the contrary, embodiments that include, contain, or have one or more elements with a particular property may include additional such elements that do not have that property. And when broad descriptive adverbs such as “substantially” and “generally” are used herein to modify adjectives, these adverbs mean “most,” “mainly,” “largely,” “to a considerable extent,” “to a large degree,” and / or “at least 51% to 99% of a possible 100% range,” and do not necessarily mean “perfect,” “complete,” “strictly,” “entirely,” or “100%.” Additionally, the term “close” may be used herein to describe the position of an object or part thereof relative to another object or part thereof, and / or to describe the positional relationship between two objects or their respective parts relative to each other, and may mean “near,” “adjacent,” “close to,” “in the vicinity,” “located,” etc.

[0080] According to this disclosure, the written description uses examples including best practices to enable those skilled in the art to manufacture and use apparatus, systems, and material compositions, and to perform methods. The following claims, including equivalents, define the scope of this disclosure.

Claims

1. A terminal arrangement structure, comprising: The substrate is made of a first electrically insulating material and has an upper surface; A generally tubular inner wall, which extends from the upper surface at its first end and terminates at its second end opposite the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius away from the central axis of the inner wall, and an annular lip extending inward from the second end; A generally tubular outer wall, which extends from the upper surface at its third end and terminates at its fourth end opposite the third end, wherein the outer wall is made of a third electrically insulating material and has an outer radius greater than the inner radius extending from the central axis, wherein the outer wall is concentric with the inner wall; A conductive ring terminal is disposed on top of the upper surface and surrounds the inner wall between the inner wall and the outer wall; and A conductive tubular terminal extends through an aperture formed in the upper surface of the substrate and has an outer circumferential surface configured to contact the inner circumferential surface of the inner wall. The outer wall is attached to the substrate in the following manner: The substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions snap into corresponding grooves in the first plurality of grooves, or The outer wall is molded as part of the substrate; and The inner wall is attached to the substrate in at least one of the following ways: The substrate has a third plurality of grooves formed in the upper surface, and the inner wall has a fourth plurality of protrusions extending radially outward from the first end, wherein the fourth plurality of protrusions engage with corresponding grooves in the third plurality of grooves. The inner wall is press-fitted onto the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on its outer circumferential surface that are wider than the orifice, to prevent the lower portion of the tubular terminal from passing through the orifice. The inner wall is molded as part of the substrate.

2. The terminal arrangement according to claim 1, wherein The first plurality of grooves, the second plurality of protrusions, the third plurality of grooves, and the fourth plurality of protrusions are each arranged circumferentially around the central axis.

3. The terminal arrangement according to claim 1, wherein The inner wall is molded as part of the substrate and covers at least a portion of the tubular terminal.

4. The terminal arrangement according to claim 1, wherein The outer wall is molded as part of the substrate, and the outer wall includes a plurality of outer wall segments arranged circumferentially around the central axis.

5. The terminal arrangement according to claim 1, wherein The inner wall and the outer wall have corresponding inner and outer heights above the top surface of the annular terminal, and the annular terminal has a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span are configured to prevent fingertips of a person exceeding a predetermined size from touching the annular terminal.

6. The terminal arrangement according to claim 1, wherein The annular lip has an annular lip thickness and defines an annular hole with an annular hole diameter, wherein the annular hole diameter and the annular lip thickness are configured to prevent fingertips of people exceeding a predetermined size from touching the tubular terminal.

7. The terminal arrangement according to claim 1, wherein The second electrical insulating material and the third electrical insulating material are the same.

8. The terminal arrangement structure according to claim 1, wherein, The first electrical insulating material, the second electrical insulating material, and the third electrical insulating material are the same.

9. The terminal arrangement structure according to claim 1, further comprising: A dielectric layer covering the substrate and having a window formed therein, through which corresponding portions of the inner wall, the outer wall, and the tubular terminal protrude.

10. The terminal arrangement structure according to claim 1, further comprising: An electrical circuit, carried by the substrate, and operatively connected to at least one of the annular terminal and the tubular terminal.

11. A terminal arrangement structure for a high-voltage battery, comprising: The substrate is made of a first electrically insulating material and has an upper surface; A generally tubular inner wall, which extends from the upper surface at its first end and terminates at its second end opposite the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius away from the central axis of the inner wall, and an annular lip extending inward from the second end; A generally tubular outer wall, which extends from the upper surface at its third end and terminates at its fourth end opposite the third end, wherein the outer wall is made of a third electrically insulating material and has an outer radius greater than the inner radius extending from the central axis, wherein the outer wall is concentric with the inner wall; A conductive ring terminal is disposed on top of the upper surface and surrounds the inner wall between the inner wall and the outer wall; A conductive tubular terminal extends through an aperture formed in the upper surface of the substrate and has an outer circumferential surface configured to contact the inner circumferential surface of the inner wall. A dielectric layer covering the substrate and having a window formed therein, with corresponding portions of the inner wall, the outer wall, and the tubular terminal protruding through the window; and An electrical circuit, carried by the substrate and operatively connected to at least one of the annular terminal and the tubular terminal; The outer wall is attached to the substrate in the following manner: The substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions snap into corresponding grooves in the first plurality of grooves, or The outer wall is molded as part of the substrate; and The inner wall is attached to the substrate in at least one of the following ways: The substrate has a third plurality of grooves formed in the upper surface, and the inner wall has a fourth plurality of protrusions extending radially outward from the first end, wherein the fourth plurality of protrusions engage with corresponding grooves in the third plurality of grooves. The inner wall is press-fitted onto the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on its outer circumferential surface that are wider than the orifice, to prevent the lower portion of the tubular terminal from passing through the orifice. The inner wall is molded as part of the substrate; The first plurality of grooves, the second plurality of protrusions, the third plurality of grooves, and the fourth plurality of protrusions are each arranged circumferentially around the central axis.

12. The terminal arrangement structure according to claim 11, wherein, The inner wall is molded as part of the substrate and covers at least a portion of the tubular terminal.

13. The terminal arrangement structure according to claim 11, wherein, The outer wall is molded as part of the substrate, and the outer wall includes a plurality of outer wall segments arranged circumferentially around the central axis.

14. The terminal arrangement structure according to claim 11, wherein, The inner wall and the outer wall have corresponding inner and outer heights above the top surface of the annular terminal, and the annular terminal has a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span are configured to prevent fingertips of a person exceeding a predetermined size from touching the annular terminal.

15. The terminal arrangement structure according to claim 11, wherein, The annular lip has an annular lip thickness and defines an annular hole with an annular hole diameter, wherein the annular hole diameter and the annular lip thickness are configured to prevent fingertips of people exceeding a predetermined size from touching the tubular terminal.

16. The terminal arrangement structure according to claim 11, wherein, The second electrical insulating material and the third electrical insulating material are the same.

17. A terminal arrangement structure for a high-voltage battery, comprising: The substrate is made of a first electrically insulating material and has an upper surface; A tubular inner wall extending from the upper surface at its first end and terminating at its second end opposite to the first end, wherein the inner wall is made of a second electrically insulating material and has an inner circumferential surface disposed at an inner radius away from the central axis of the inner wall, and an annular lip extending inward from the second end; A tubular outer wall, which extends from the upper surface at its third end and terminates at its fourth end opposite to the third end, wherein the outer wall is made of a third electrically insulating material and has an outer radius greater than the inner radius extending from the central axis, wherein the outer wall is concentric with the inner wall; A conductive ring terminal is disposed on top of the upper surface and surrounds the inner wall between the inner wall and the outer wall; and A conductive tubular terminal extends through an aperture formed in the upper surface of the substrate and has an outer circumferential surface configured to contact the inner circumferential surface of the inner wall. The outer wall is attached to the substrate in the following manner: the substrate has a first plurality of grooves formed in the upper surface, and the outer wall has a second plurality of protrusions extending radially outward from the third end, wherein the second plurality of protrusions engage with corresponding grooves in the first plurality of grooves; and The inner wall is attached to the substrate by press-fitting the inner wall to the upper portion of the tubular terminal, and the tubular terminal has one or more shoulders on the outer circumferential surface that are wider than the orifice to prevent the lower portion of the tubular terminal from passing through the orifice.

18. The terminal arrangement structure according to claim 17, wherein, The inner wall and the outer wall have corresponding inner and outer heights above the top surface of the annular terminal, and the annular terminal has a radial span between the inner wall and the outer wall, wherein the inner height, the outer height, and the radial span are configured to prevent fingertips of a person exceeding a predetermined size from touching the annular terminal.

19. The terminal arrangement structure according to claim 17, further comprising: A dielectric layer covering the substrate and having a window formed therein, through which corresponding portions of the inner wall, the outer wall, and the tubular terminal protrude.

20. The terminal arrangement structure according to claim 19, further comprising: An electrical circuit, carried by the substrate, and operatively connected to at least one of the annular terminal and the tubular terminal.

Images