Flat Insulated Battery Connector for Low-Height Module Linking
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Solution Overview
Problem
High-voltage battery modules in electric vehicles require large installation space due to protruding electric-shock-protected terminals, which increases structural height and complicates modular connections.
Innovation Solution
A battery connector with a flat, rail-like busbar and insulating coatings, featuring cutouts and captive nuts for secure pole pin insertion, reduces installation space height while providing electric-shock protection without additional height requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric-shock-protected high voltage terminals are used for battery module connections, then electric-shock protection is improved, but installation space height increases
Solution Approach 1:
The busbar is designed as a flat, planar component with the main plane of extent oriented horizontally. The insulating coating is applied to the top surface in the connecting region, providing electric-shock protection in the vertical dimension without increasing horizontal footprint. This dimensional reorganization allows protection without height increase.
Solution Approach 2:
The insulating coating is applied selectively only to the connecting region of the busbar, not the entire structure. The contact regions remain exposed for electrical connection, while only the intermediate connecting portion receives insulation. This localized application provides necessary protection without unnecessary material or height increase.
2Quantity of substance
If larger battery modules are used to increase voltage and capacitance, then energy density is improved, but terminal protrusion increases installation space requirements
Solution Approach 1:
The busbar采用扁平化设计，主延伸面为水平面，将传统的三维立体结构转变为二维平面结构。这种维度转变使得连接器可以在保持相同电气功能的前提下，大幅减少垂直方向的空间占用，从而解决大容量电池模块与紧凑安装空间之间的矛盾。
Solution Approach 2:
通过改变连接器的几何参数，特别是将高度维度压缩，使busbar在垂直方向的尺寸远小于其长度和宽度。这种参数优化使得连接器能够在不牺牲电气性能的情况下，适应更紧凑的安装空间要求。
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
Enables secure, electric-shock-protected connections between battery modules with reduced installation space, allowing for higher current conduction and efficient heat dissipation, thus optimizing the structural design of electric vehicles.
Implementation Method 1
The connecting region has an electrically insulating coating
Data Source
AI summary
A battery connector (1) is provided for electrically contact-connecting a first pole pin (19) of a first battery module (10) to a second pole pin (20) of a second battery module (10′). The battery connector (1) has a busbar (1′) with a first contact region (2), a second contact region (3) and a connecting region (4) arranged between the first contact region (2) and the second contact region (3) in a main direction of extent (H) of the busbar (1′). The connecting region (4) has an electrically insulating coating. The first contact region (2) and the second contact region (3) each have a cutout (5). The cutouts (5) are open in an insertion direction (E) that is parallel to a main plane of extent (HE) of the busbar (1′) and orthogonal to the main direction of extent (H).