Integrated High-Voltage Box Terminals to Eliminate Secondary Mating
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Solution Overview
Problem
The assembly process of high-voltage boxes in batteries is complex and time-consuming due to the need for secondary mating between conductive connection parts and terminals, which affects the assembly efficiency and rate of the battery.
Innovation Solution
The high-voltage box integrates terminals and conductive connection parts, eliminating the need for secondary mating, and incorporates snap-fit connections and injection molding for enhanced stability and simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conductive connection parts and terminals are assembled separately with secondary mating, then connection flexibility is improved, but assembly complexity and time increase
Solution Approach 1:
The patent combines the conductive connection part and terminal into a single integrally formed electric connector component. This eliminates the secondary mating step between separate parts, reducing assembly complexity while maintaining the functional capabilities of both connection elements through their integrated design
2Ease of manufacture
If conductive connection parts and terminals are assembled separately, then manufacturing flexibility is improved, but assembly time and rate decrease
Solution Approach 1:
The electric connector integrates the conductive connection part and terminal as one component, eliminating multiple assembly steps and significantly improving battery assembly rate. The integrated manufacturing process maintains flexibility through modular design while reducing the number of discrete assembly operations required
Solution Approach 2:
The conductive connection part and terminal are pre-integrated into a single electric connector component before assembly into the battery. This preliminary integration eliminates the need for secondary mating during final assembly, directly improving assembly productivity
3Reliability
If multiple assembly steps including secondary mating are used, then connection stability is improved, but assembly process complexity increases
Solution Approach 1:
By integrating the conductive connection part and terminal into one component, the patent reduces assembly process complexity while ensuring connection stability through the integral structure that eliminates potential misalignment issues from secondary mating operations
Data Source
AI summary
A high-voltage box comprises: a first housing, having a wall portion and an accommodating space enclosed by the wall portion, wherein the accommodating space is used for accommodating an electrical device; an electrical connector, disposed in the first housing, the electrical connector comprising a plurality of terminals and a conductive connection portion, wherein the conductive connection portion is connected to at least one terminal and is integrally formed with the terminal, and the terminals are used for connecting the electrical device.