Manual Service Disconnect Terminal Structure for EV Battery Systems
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Solution Overview
Problem
Existing manual service disconnects for electric vehicle battery systems have complex internal structures, limited conducting capacity, and are not easily reducible in size or weight, making them inefficient for repair and integration into compact battery systems.
Innovation Solution
A manual service disconnect design featuring a plate-shaped upper bus bar terminal and a lower bus bar terminal with alternating plug and contact parts, allowing for increased contact area and simplified assembly, reducing size and weight while maintaining high conducting capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the manual service disconnect uses a traditional internal structure with multiple separate terminals, then the conducting capacity is limited and the structure is complex, but the contact area is reduced and the device size is increased
Solution Approach 1:
The patent merges multiple separate terminals into a single integrated terminal structure. The terminal includes a body portion with first and second contact portions that are electrically connected, and a protruding portion that extends from the body portion. This integration reduces the number of separate components while maintaining multiple contact points, thereby simplifying the internal structure and increasing the overall contact area with the battery pack electrode.
2Volume of moving object
If the manual service disconnect is designed with a compact structure, then the device size is reduced, but the conducting capacity is limited
Solution Approach 1:
The patent utilizes three-dimensional spatial arrangement to increase conducting capacity within a compact volume. The terminal structure includes a body portion with contact portions arranged in specific spatial relationships, and a protruding portion that extends in a direction away from the battery pack. This dimensional arrangement allows multiple contact points to be distributed in space, increasing the effective contact area and conducting capacity without proportionally increasing the device volume.
3Ease of repair
If the manual service disconnect uses a simplified terminal structure, then the device size is reduced and repair is easier, but the contact area may be insufficient
Solution Approach 1:
The terminal structure is segmented into distinct functional portions: a body portion containing first and second contact portions, and a protruding portion extending from the body. This segmentation allows each portion to be optimized for its specific function while maintaining overall structural simplicity. The first contact portion contacts the battery pack electrode, the second contact portion provides additional contact, and the protruding portion extends to facilitate connection and disconnection operations, thereby enabling easy repair while maintaining sufficient contact area.
Data Source
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AI summary
Disclosed is a manual service disconnect comprising: an upper housing which has thereinside a plate-shaped upper bus bar terminal; and a lower housing comprising a lower bus bar terminal of which the top is opened so as to be coupled to the upper housing, the lower bus bar terminal having thereinside a first bus bar terminal and a second bus bar terminal which, when being coupled to the upper housing, electrically contact, in the form of a slot, the upper bus bar terminal on the front surface and the rear surface, wherein the first bus bar terminal comprises a first contact part which contacts the upper bus bar terminal and a first plug part extending from the first contact part, and the second bus bar terminal comprises a second contact part which contacts the upper bus bar terminal and a second plug part extending from the second contact part.