Battery Case Grounding and Terminal Cover Interlock

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Solution Overview

Problem

The existing battery terminal connection methods to a vehicle body can lead to short circuits between the positive and negative terminals, and the use of additional harnesses increases costs and the risk of forgotten connections.

Innovation Solution

A battery design where the negative terminal is electrically connected to the vehicle body through a conductive battery case, with a ground member and terminal covers that prevent exposure of the positive terminal, reducing the need for additional harnesses and preventing short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the minus terminal is connected to the vehicle body via a harness, then the connection is reliable, but the number of harnesses increases and cost increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidnumber of harnesses

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the electrical connection function with the mechanical mounting function by making the battery case itself electrically conductive and using it as the ground connection path. The battery case serves dual purposes: containing the battery cells and providing the ground connection to the vehicle body through mounting brackets, eliminating the need for separate harnesses.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery case is designed with multi-functionality, serving both as the structural container for battery cells and as the electrical ground connection component. The mounting brackets that mechanically attach the battery case to the vehicle body also serve as electrical conductors, combining mechanical and electrical functions into single components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If the minus terminal is connected to the vehicle body via the battery case, then the number of harnesses is reduced, but the risk of short circuit between plus terminal and battery case increases

Engineering Contradiction:

Improvenumber of harnessesVSAvoidshort circuit risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent segments the terminal access areas by providing separate covers for the plus terminal and minus terminal. The plus terminal cover and minus terminal cover are positioned such that they prevent simultaneous contact with tools, dividing the potential short circuit path into separate, protected zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces terminal covers as intermediary protective elements between the exposed terminals and external tools. These covers act as physical barriers that prevent direct contact between conductive tools and the terminals, thereby mediating against the harmful short circuit effect.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If terminal protection sections are provided to prevent short circuits, then short circuit prevention is achieved, but the device complexity increases

Engineering Contradiction:

Improveshort circuit preventionVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines the terminal protection function with the existing terminal covers that are already part of the battery assembly. Rather than adding separate protection mechanisms, the design integrates short circuit prevention into the functional covers that already seal and protect the terminals during normal operation.

Inventive Principle:

Principle #5Merging (Combining)

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 design effectively prevents short circuits between the positive and negative terminals while eliminating the need for additional harnesses, reducing costs and ensuring reliable connections.

Implementation Method 1

a ground member that is attached to the minus terminal so as to electrically connect the minus terminal and the battery case

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

In a state where the ground member is attached to the minus terminal, the ground member abuts the plus terminal cover, and thus exposure of the plus terminal is restricted by the plus terminal cover

Methodology Applied

Scientific EffectMechanical contact force: Mechanical Force

Data Source

PatentUS11495857B2Battery and methods for connecting/disconnecting conductive wire to/from battery

Publication Date: 2022.11.08 MAZDA MOTOR CORP

AI summary

A battery mounted on a vehicle, the battery including a battery case having an electrically conductive material and configured to be attached to a body of the vehicle so as to electrically connect to the body of the vehicle. The battery case includes a plus terminal to which an electrical conductor is connected to supply electric power to electrical equipment on-board the vehicle, a minus terminal, a ground member that is attached to the minus terminal so as to electrically connect the minus terminal and the battery case, and a plus terminal cover that covers the plus terminal. In a state where the ground member is attached to the minus terminal, the ground member abuts the plus terminal cover so as to restrict a movement of the plus terminal cover from exposing the plus terminal.