EV Battery Terminal Holder with Integrated Rail Insulation
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Solution Overview
Problem
Conventional electric vehicle battery assemblies face challenges in ensuring proper electrical insulation between battery cells and rails, often requiring additional insulating components that increase manufacturing complexity and costs.
Innovation Solution
A terminal holder made of dielectric material with integrated side and upper rail protection portions, featuring flanges that extend from the main body to directly contact the rails and cells, providing effective insulation without the need for separate insulating structures like dedicated rail covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated rail covers are used to electrically insulate cells from rails, then electrical insulation reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The terminal holder is merged with rail protection portions that provide electrical insulation between the rails and battery cells. The side rail protection portion and upper rail protection portion are integrated into the terminal holder structure, eliminating the need for separate dedicated rail covers while maintaining insulation reliability.
Solution Approach 2:
The terminal holder serves multiple functions: it holds the terminal, provides electrical insulation between the terminal and cell, and protects the rails from direct contact with cells through integrated side rail protection and upper rail protection portions. This multi-functionality eliminates the need for separate insulating components.
2Reliability
If dedicated rail covers are used to electrically insulate cells from rails, then electrical insulation reliability is improved, but manufacturing cost increases
Solution Approach 1:
The terminal holder is merged with rail protection portions that provide electrical insulation between the rails and battery cells. The side rail protection portion and upper rail protection portion are integrated into the terminal holder structure, eliminating the need for separate dedicated rail covers while maintaining insulation reliability.
Solution Approach 2:
The terminal holder serves multiple functions: it holds the terminal, provides electrical insulation between the terminal and cell, and protects the rails from direct contact with cells through integrated side rail protection and upper rail protection portions. This multi-functionality eliminates the need for separate insulating components.
3Reliability
If separate insulating components are used, then electrical insulation is ensured, but assembly complexity increases
Solution Approach 1:
The terminal holder is merged with rail protection portions that provide electrical insulation between the rails and battery cells. The side rail protection portion and upper rail protection portion are integrated into the terminal holder structure, eliminating the need for separate dedicated rail covers while maintaining insulation reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures reliable electrical insulation, reducing the risk of shorts and eliminating the need for additional insulating components, thereby simplifying assembly and reducing manufacturing costs.
Implementation Method 1
A terminal holder for an electric vehicle battery assembly is made of dielectric material
Data Source
AI summary
An electric vehicle battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a battery cell, a rail securing the cell, and a terminal holder in direct contact with the rail.