Battery Module Connector With Integrated Contact Protection
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Solution Overview
Problem
Existing module connectors for battery modules face challenges in ensuring reliable electrical insulation and preventing electric shocks during assembly, as insulating coatings are complex to produce and prone to damage.
Innovation Solution
A module connector design featuring a contact protection element that covers the connecting conductor and a fastening element, which is pre-assembled with the contact protection element, providing secure contact protection without additional components, and allowing for simple assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrically insulating coating is applied to the fastening element, then contact protection is provided, but the production becomes complex and the coating can be easily damaged
Solution Approach 1:
The contact protection element and fastening element are merged into a single integrated component. The contact protection element forms an integral part of the fastening element, eliminating the need for separate insulating coatings and reducing production complexity while maintaining reliable electrical insulation.
Solution Approach 2:
The fastening element is constructed as a composite structure with an electrically insulating contact protection element and an electrically conductive fastening portion. This composite design provides both electrical insulation and mechanical fastening functions without requiring delicate surface coatings.
2Reliability
If a separate electrically insulating coating is used, then contact protection is achieved, but additional assembly steps and components are required
Solution Approach 1:
The contact protection element and fastening element are combined into one integrated component, reducing the total number of parts and assembly steps while ensuring reliable contact protection through the integrated insulating structure.
3Productivity
If the fastening element is pre-assembled with the contact protection element, then assembly time is shortened, but the structure becomes more complex
Solution Approach 1:
The contact protection element and fastening element are merged into a single pre-assembled unit with a straightforward integrated structure. This merging reduces assembly time without significantly increasing structural complexity, as the integration follows a simple and logical design.
4Reliability
If the contact protection element covers the contact region, then electrical insulation is ensured, but the handling and assembly become more difficult
Solution Approach 1:
The fastening element is designed with a movable structure that allows the contact protection element to be dynamically adjusted during assembly. The head portion can be moved relative to the shank portion, enabling easy handling and assembly while maintaining electrical insulation when in the covering position.
Data Source
AI summary
In order to create a module connector for electrically conductively connecting at least two battery modules, comprising a connecting conductor, which has a contact region that is arrangeable on a contact element of a battery module, in which module connector a sufficient contact protection for a fastening element is ensured in a simple and reliable manner, it is proposed that the module connector comprises a contact protection element, which at least partially covers the contact region of the connecting conductor, and a fastening element for fixing the contact region of the connecting conductor to the contact element, wherein the fastening element in a rest position is held on the contact protection element and is transferable from the rest position into an assembly position in which a contact protection is provided for at least a protected part of the fastening element by the contact protection element.