Finger-proof Battery Terminals with Insulating Jackets
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Solution Overview
Problem
Current rechargeable battery modules in electric vehicles face safety hazards due to exposed high-voltage electrical terminals that can be inadvertently contacted by operators or tools, leading to potential shock or damage during assembly and operation.
Innovation Solution
The implementation of finger-proof electrical terminals with low-profile, shielding features that integrate with an interconnect board assembly to prevent accidental contact, using complementary insulating designs such as overmolded, snap-fit, or clamshell configurations to create a safe standoff distance between the terminal and the busbar, while allowing for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical terminals are exposed for easy connection, then ease of operation is improved, but safety is worsened due to risk of inadvertent contact
Solution Approach 1:
An electrically insulating housing is introduced as an intermediary component between the electrical terminal and the external environment. The housing includes a receptacle that receives the electrical terminal and a window that selectively exposes the contact surface, thereby mediating between the need for connection access and the need for safety protection.
Solution Approach 2:
The housing structure implements local quality by differentiating between exposed and protected regions. The window portion locally exposes the contact surface for connection purposes, while the surrounding housing structure provides insulation and protection, creating localized access without compromising overall safety.
2Object-affected harmful factors
If shielding features are added to prevent contact, then safety is improved, but device complexity increases
Solution Approach 1:
The housing structure merges multiple functions into a single component: it provides mechanical support for the electrical terminal, electrical insulation, safety shielding, and controlled access through the window. This consolidation achieves safety protection without proportionally increasing complexity.
Solution Approach 2:
The housing serves multiple purposes simultaneously: it acts as a mounting structure for the terminal, provides electrical insulation, creates safety shielding, and enables controlled access through its window design. This multi-functionality reduces the need for separate protective components.
3Object-affected harmful factors
If insulating housing is added to protect terminals, then safety is improved, but manufacturing complexity increases
Solution Approach 1:
The housing is segmented into functional regions (receptacle, window, shield portions) that can be designed and manufactured as modular elements. This segmentation allows for standardized manufacturing processes and simplifies assembly of the terminal within the housing structure.
Data Source
AI summary
Presented are finger-proof electrical terminals for battery assemblies, methods for making/using such electrical terminals, and vehicles with battery modules having finger-proof electrical terminals for bolted busbar connections. A battery assembly includes one or more electrochemical battery cells and one or more electrical terminals each electrically connected to the battery cell(s) and having a contact face to electrically connect the battery assembly to an electrical connector. A threaded nut attaches each electrical terminal to one of the electrical connectors. An electrically insulating nut cap is attached to each threaded nut. A battery housing, which stores therein the battery cell(s), includes an electrically insulating housing wall with one or more terminal jackets each mounting therein one of the electrical terminals. Each terminal jacket has a jacket window that circumscribes one of the nut caps, spaced therefrom by a predefined clearance sufficient to expose the contact face of the electrical terminal.