High Voltage Battery Attachment Overlap Gap Design
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Solution Overview
Problem
Existing high-voltage storage devices for motor vehicles face challenges in providing adequate protection against accidental contact while allowing gases to escape, with existing solutions being costly and requiring additional insulation or gas discharge ducts.
Innovation Solution
A high-voltage storage device design featuring an attachment that overlaps the wall of the energy storage module without contact, creating a small gap for gas escape, eliminating the need for separate gas discharge ducts and additional insulation, and using plastic injection molding for cost-effectiveness and complex design capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate gas discharge ducts and additional insulation are used, then protection against contact and gas escape are ensured, but manufacturing costs and device complexity increase
Solution Approach 1:
The attachment combines multiple functions into a single component: it provides electrical insulation, creates protective overlap to prevent contact, and enables gas discharge through integrated gaps. This merging eliminates the need for separate insulation layers and gas discharge ducts, reducing device complexity while maintaining reliability
Solution Approach 2:
The attachment serves multiple purposes simultaneously: it insulates electrical connections, physically protects storage cells through overlapping design, and facilitates gas escape through built-in gaps. This multi-functionality replaces what would traditionally require multiple separate components, reducing both complexity and manufacturing costs
2Object-generated harmful factors
If separate gas discharge ducts are used, then gas escape is ensured, but manufacturing costs increase
Solution Approach 1:
The gas discharge function is merged into the attachment structure through integrated gaps, eliminating the need for separate gas discharge ducts. This reduces the number of components and assembly steps, directly lowering manufacturing costs while ensuring effective gas escape
Solution Approach 2:
The attachment's own structure provides the gas discharge pathway through its gaps, without requiring external or additional components. The attachment serves itself by incorporating the gas escape function directly into its design, simplifying manufacturing
3Reliability
If additional insulation is used, then protection against contact is ensured, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The insulation function is merged into the attachment material itself, which is made of electrically insulating plastic. This eliminates the need for separate insulation layers or materials, reducing both manufacturing complexity and assembly steps while ensuring adequate protection against contact
Solution Approach 2:
The attachment material inherently provides electrical insulation through its plastic composition, without requiring additional insulation components. The attachment serves its own insulation needs through its material properties, simplifying manufacturing and assembly
Data Source
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AI summary
The invention relates to a high voltage battery (1) for supplying power, in particularly of a motor vehicle, comprising an energy storage module (2) with several electrochemical storage cells (3) and a wall (6, 7) housing the plurality of storage cells (3), each storage cell (3) comprising at least two electric connection terminals (4, 5), and an upper part (8) for contacting and covering the connection terminal (4, 5), said upper part (8) overlapping the wall (6, 7) contactlessly such that a gap (11) remains to the storage cells (3).