EV Battery Connection Assembly with Press-Fit Terminals
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Solution Overview
Problem
Current electric vehicle batteries face challenges with high costs and technological inadequacies, particularly in terms of power output stability and assembly efficiency, which hinder their widespread adoption.
Innovation Solution
A connection assembly comprising a bracket, circuit board, connector, press-fit terminal, detection element, and insulation displacement connection terminal, with a filler for secure electrical connections and enhanced sealing, facilitating stable and efficient transmission of electrical signals and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional connection assemblies are used, then the battery module can be assembled, but the assembly efficiency is low and manufacturing costs are high
Solution Approach 1:
The patent combines the connector, detection element, and insulation displacement connection terminal into an integrated connection assembly that is pre-assembled on a circuit board. This merging of multiple components into a single modular unit significantly improves assembly efficiency by reducing the number of separate assembly steps while lowering manufacturing costs through standardized production of the integrated module.
Solution Approach 2:
The connection assembly is pre-assembled with the circuit board, detection element, and terminals configured in advance before being installed into the battery module. This preliminary preparation of the connection assembly allows for faster on-site installation and reduces assembly time during battery module manufacturing.
2Reliability
If simple connection structures are used, then manufacturing costs are reduced, but the connection stability and electrical connection reliability are insufficient
Solution Approach 1:
The patent integrates multiple functions (electrical connection, detection, insulation) into a single connection assembly structure. This merging approach improves connection stability by ensuring all components are precisely positioned and secured together, while the integrated design actually simplifies the overall structure compared to having separate components that need to be aligned and assembled.
Solution Approach 2:
The circuit board serves as an intermediary structure that provides a stable mounting platform for the connector and detection element. This intermediary structure ensures reliable electrical connections and mechanical stability without requiring complex direct connections between all components.
3Productivity
If press-fit terminals are used, then assembly efficiency is improved, but the connection integrity and insulation performance may be compromised
Solution Approach 1:
The insulation displacement connection terminal acts as an intermediary between the press-fit terminal and the circuit board. It provides both electrical connection and insulation functions, ensuring that the press-fit connection maintains integrity while preventing electrical short circuits through its insulating properties.
Solution Approach 2:
The connection assembly uses composite construction with conductive materials for electrical connections and insulating materials for isolation. This composite approach ensures both connection integrity and insulation performance are maintained simultaneously, allowing for efficient assembly without compromising reliability.
Data Source
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AI summary
The present disclosure provides a connection assembly. The connection assembly comprises a bracket, a circuit board, a connector, and a press-fit terminal. The circuit board is disposed on the bracket and provided with a press-fit through-hole. The connector is disposed on the bracket, and configured for electrically connecting a battery cell. The press-fit terminal has a connection end and a press-fit end. The connection end is electrically connected with the connector. The press-fit end extends into at least part of the press-fit through-hole and is electrically connected with the circuit board. The connection assembly of the present disclosure is stable in connection and may conveniently transmit voltage, current, and various other electrical signals. The connection assembly is convenient to assemble and saves manufacturing costs.