Insulated Battery Module Housing with Integrated Contact Element
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery systems lack safe handling mechanisms, particularly for battery modules with risk of electric shock and acid leakage, which poses hazards to users during assembly and operation.
Innovation Solution
A battery device and system where the battery module is enclosed in an insulating, acid-proof housing with a contact element connected to the positive and negative poles, allowing safe connection to an electronics unit via a contactor that prevents electrical energy transfer unless properly connected, thus minimizing user risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery module is provided with exposed positive and negative poles for electrical connection, then the electrical connection to electronics unit is facilitated, but the user faces risk of electric shock
Solution Approach 1:
The patent introduces an insulating housing as an intermediary element between the battery module's electrical poles and the user. The housing includes integrated contact elements that serve as mediators for electrical connection, allowing current flow through isolated pathways that prevent direct contact with live poles. This resolves the contradiction by maintaining electrical connectivity while eliminating shock risk through the insulating barrier.
Solution Approach 2:
The patent extracts the hazardous function (direct electrical contact) from the battery module by separating the connection function into distinct contact elements embedded in the insulating housing. The live poles are enclosed and isolated, with only the necessary contact surfaces exposed through the insulating material, thereby removing the electric shock hazard while preserving electrical connectivity.
2Ease of operation
If the battery module is handled without protective housing, then the handling process is simpler, but the user is exposed to acid leakage hazards
Solution Approach 1:
The insulating housing serves as a protective intermediary between the battery module's acid-containing components and the user. The housing material acts as a barrier that prevents acid contact while allowing the user to handle the battery module safely. The integrated contact elements provide connection functionality through this protective barrier, maintaining simplicity while adding protection.
Solution Approach 2:
The patent employs composite construction by integrating conductive contact elements within an insulating and acid-resistant housing material. This composite structure provides multiple functions simultaneously: electrical isolation, acid protection, and controlled electrical connection, all while maintaining a simple external form for easy handling.
3Reliability
If the battery module is fully enclosed in insulating housing with contact elements, then user safety is improved, but the device structure becomes more complex
Solution Approach 1:
The patent merges multiple protective and functional elements into a single integrated insulating housing structure. The housing combines insulation, acid protection, and electrical connection functions in one unified component. The contact elements are embedded directly in the housing rather than being separate attachments, simplifying the overall structure while maintaining comprehensive safety and functionality.
Solution Approach 2:
The insulating housing is designed as a multi-functional universal component that simultaneously provides electrical isolation, chemical protection, mechanical support, and electrical connection interfaces. This multi-functionality reduces the need for additional separate protective components, thereby limiting the increase in structural complexity while achieving comprehensive safety.
Data Source
AI summary
A battery device with a battery module that includes multiple secondary cells, and the battery module is provided with a positive pole and a negative pole. Moreover, the battery module is placed inside an insulating housing with a contact element, which is connected to the positive pole and to the negative pole and through which the positive pole and the negative pole may be connected to an electronics unit of a battery system. Moreover, the invention relates to a battery system and a method for assembling a battery system.