Battery Module Relay Terminal Stability via Segmented Connection
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Solution Overview
Problem
Battery modules for electric and hybrid electric vehicles face issues with terminal position instability due to external impacts, which can lead to damage and reduced durability.
Innovation Solution
A battery module design that includes a relay system with output terminals connected via connection bars and fastened to the case using polygonal-shaped mounting plates and grooves, preventing terminal rotation and ensuring stability even under external torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the output terminal is connected directly to the relay body, then the connection is simple and compact, but the terminal position becomes unstable under external impact
Solution Approach 1:
The connection structure is divided into separate components: the relay body, the connection bar, and the output terminal. This segmentation allows each component to perform its specific function independently, with the connection bar acting as a stable anchor point spaced apart from the relay body, preventing terminal position instability under external impact.
Solution Approach 2:
The connection bar serves as an intermediary element between the relay body and the output terminal. It is fastened to the case at a location spaced apart from the relay body, providing a stable intermediate connection point that prevents direct transmission of external impacts to the terminal, thereby maintaining position stability.
2Volume of moving object
If the relay is installed close to the output terminal, then the overall size is reduced, but external impacts cause rotation and position errors
Solution Approach 1:
The connection bar is fastened to the case at an asymmetric location that is spaced apart from the relay body, creating an optimized distance relationship. This asymmetric positioning provides sufficient separation to prevent rotation under external impact while maintaining compact overall dimensions of the battery module.
Solution Approach 2:
The connection bar extends in a spatial dimension away from the relay body, creating a three-dimensional arrangement rather than a planar one. This dimensional separation allows the terminal to be positioned stably without requiring excessive overall module size, as the stability is achieved through spatial distribution rather than simply increasing distance.
Data Source
AI summary
A battery module including: a battery assembly including a plurality of rechargeable batteries; a case receiving the battery assembly; a battery management system (BMS) managing unit batteries of the battery assembly; and a relay installed to the case on an output line of the battery assembly and including a relay body configured to selectively block a current according to a signal of the BMS; a connection bar connected to the relay body; and an output terminal connected to the relay body via the connection bar and fastened to the case at a location spaced apart from the relay body.