Battery Terminal Connector With Visual Latch Lock Indication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection methods for battery modules in high-voltage electrical energy storage systems, such as those in electric vehicles, often lack security and visibility in assembly, making them unsuitable for high manufacturing volumes.
Innovation Solution
A connection device featuring a longitudinal insulation body with terminal receiving housings and a latch system that secures an electrical connector between a terminal and a conductor, including a visual lock indicator to ensure secure and observable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar is screwed or soldered to the terminals of the modules, then electrical connection is achieved, but assembly security and visibility are insufficient for high manufacturing volumes
Solution Approach 1:
The patent employs a visual indicator element that changes its appearance or position to provide clear visual feedback about the connection status. This allows operators to immediately verify proper assembly without complex inspection procedures, directly addressing the visibility issue while maintaining secure connections
Solution Approach 2:
The patent incorporates visual feedback mechanisms through indicators that show whether the electrical connector is properly engaged and locked. This immediate feedback system enables operators to confirm correct assembly during high-volume manufacturing, solving the visibility problem while ensuring reliable connections
2Productivity
If a pluggable connection device with holding clips is used, then assembly speed is improved, but connection security and lockability are insufficient
Solution Approach 1:
The patent employs a dynamic latch mechanism that transitions between locked and unlocked states, providing secure retention while allowing easy insertion and removal. This dynamic system maintains connection security during operation while enabling rapid assembly changes, resolving the contradiction between speed and security
Solution Approach 2:
The connection device is divided into functional segments including insertion portions, holding clips, and latch mechanisms. This segmentation allows each component to perform its specific function optimally - the holding clips provide immediate retention upon insertion while the latch mechanism provides secure locked positioning, achieving both speed and security
3Reliability
If means are added to prevent electrical disconnection and enable visual observation, then connection security and visibility are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into integrated components: the visual indicator is merged with the latch mechanism itself rather than being a separate system, and the locking and indicating functions are combined in a single mechanical assembly. This integration provides secure connections and visual feedback without proportionally increasing overall device complexity
Solution Approach 2:
The latch mechanism serves multiple functions simultaneously: it provides the locking action to secure the electrical connector, it positions the visual indicator to show connection status, and it maintains electrical contact pressure. This multi-functionality reduces the need for separate components, minimizing complexity while achieving security and visibility goals
Data Source
AI summary
A device for connecting a terminal of a battery module to an electrical conductor comprises a longitudinal insulation body having at least one housing for receiving the terminal, and an electrical conductor arranged in the longitudinal insulation body. The connection device further comprises a connection arrangement including an electrical connector configured to be inserted into the housing and to make electrical contact between the terminal and the electrical conductor in order to electrically connect them, and a latch. A visual lock indicator is disposed on the longitudinal insulation body so as to be at least partially concealed by the latch in a first latch position and to be fully exposed in a second latch position.