Traction Battery Electrical Joint Insert
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical joints in traction batteries of electrified vehicles require more packaging space due to the design of existing solutions, which can be inefficient and lead to increased complexity.
Innovation Solution
An electrical joint assembly that includes an insert held by an array plate, where the insert is in electrical communication with a bus bar, and a fastener secures the bus bar and electric cable connector, reducing the overall packaging size by integrating the components within the array plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional electrical joint designs are used in traction batteries, then electrical connection is achieved, but packaging space is increased and system complexity is enhanced
Solution Approach 1:
The patent combines the electrical joint components (insert, bus bar, cable connector) into a single integrated assembly that fits within the array plate structure. The insert is held by the array plate and electrically connects the bus bar to the cable connector, merging multiple separate components into one compact unit that reduces packaging space while maintaining electrical functionality.
Solution Approach 2:
The electrical joint components are nested within the array plate structure. The insert is held by the array plate, and the bus bar and cable connector are positioned around the insert, creating a nested arrangement where smaller components are contained within or around larger structural elements, thereby minimizing the overall packaging volume.
2Volume of moving object
If electrical joints are integrated within the array plate, then packaging size is reduced, but manufacturing complexity increases
Solution Approach 1:
The electrical joint assembly is segmented into distinct functional components (insert, bus bar, cable connector) that can be manufactured separately using standard processes, then assembled together. This segmentation allows each component to be optimized for its specific manufacturing requirements while maintaining overall integration within the array plate.
Solution Approach 2:
The array plate serves multiple functions: it provides structural support for the battery cells and simultaneously holds the electrical joint insert. This multi-functionality reduces the need for separate mounting structures and simplifies the overall manufacturing process by combining structural and electrical functions into a single component.
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
The solution reduces the packaging size required for electrical joints, providing a more compact and efficient electrical coupling system that minimizes the need for additional shielding and reduces the profile of the joint, enhancing the integration within the traction battery array.
Implementation Method 1
The insert is in electrical communication with a bus bar of the traction battery
Implementation Method 2
The array plate comprises a non-conductive material, and the insert comprises a metallic material
Data Source
AI summary
An exemplary assembly includes an array plate of a traction battery and an insert held by the array plate. The insert is in electrical communication with a bus bar of the traction battery. Another exemplary assembly includes an array plate of a traction battery and a fastening insert recessed within the array plate. The fastening insert is more electrically conductive than the array plate.