Insulating Connection Member for Battery Modules

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Solution Overview

Problem

Existing connection systems for battery modules require handling high voltage portions, necessitating insulation measures and often a dedicated tool for secure electrical connections and disconnections.

Innovation Solution

A connection member comprising an insulating member with through holes and a fastening bolt system that allows for electrical connection and disconnection of battery modules without touching high voltage areas, using common tools and preventing wear on the fixing member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a bolt connection system is used to electrically connect adjacent battery modules, then electrical connection is achieved, but insulation measures are required due to high voltage exposure

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidhigh voltage exposure risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

An insulating member is introduced as an intermediary component between the bolt connection system and the battery modules. This insulating member includes through-holes that allow the bolt to pass through and secure the connection, while simultaneously isolating the high-voltage bus bars from direct contact with the bolt and surrounding structures, thereby eliminating the need for additional insulation measures like insulating gloves

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating member serves multiple functions simultaneously: it provides electrical insulation to protect against high voltage, structural support to hold the bus bars in position, and a mounting interface for the bolt connection system. By combining these functions into a single component, the design simplifies the overall connection system while maintaining safety and reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a bolt is used to fasten the connection, then secure electrical connection is achieved, but a dedicated tool is required to ensure contact pressure

Engineering Contradiction:

Improvecontact pressure at electrical connectionVSAvoidtool requirement for connection

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connection system transitions from a static fastening method to a dynamic one using a threaded bolt that can be screwed in and out. The bolt threads engage with corresponding threaded holes in the insulating member, allowing the bolt to be manually tightened to achieve the required contact pressure without specialized tools, and easily removed when disconnection is needed

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If the connection member is made detachable for disconnection, then electrical disconnection is enabled, but wear on the fixing member occurs due to repeated attachment and detachment

Engineering Contradiction:

Improveelectrical connection and disconnection capabilityVSAvoidfixing member service life

Core Design Contradiction:

Adaptability or versatilityVSDuration of action of stationary object

Solution Approach 1:

The detachable connection functionality is extracted from the main insulating member and implemented through a separate bolt that can be inserted and removed. The bolt engages with threaded holes that are pre-formed in the insulating member, allowing the connection to be made and broken without wearing down the insulating member itself, thereby extending the service life of the stationary component

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS10818904B2Connection member

Publication Date: 2020.10.27 TOYOTA JIDOSHA KK

AI summary

A through hole is provided in an insulating member. A bus bar is provided in the insulating member and constructed to electrically connect adjacent modules to each other when the insulating member is attached to a fixing member. A fastening bolt fastens the insulating member to the fixing member by being coupled to a nut through the through hole. A nut is provided in the through hole, and the through hole is provided to extend toward the fixing member when the insulating member is attached to the fixing member.