Insulating Mechanical Retaining Element for Vehicle Battery Current Sensor
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Solution Overview
Problem
Existing solutions for attaching current sensors to vehicle batteries face challenges in providing both secure mechanical support and electrical insulation without increasing part costs and assembly complexity, particularly under dynamic loads and extreme conditions.
Innovation Solution
A mechanical holding element made of electrically insulating plastic, featuring form-locking elements and a positive-locking mechanism, which provides stability in specific directions while minimizing part count and assembly effort, and is designed to accommodate manufacturing tolerances and dynamic loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections are used for mechanical support, then mechanical stability is improved, but device complexity and assembly effort increase
Solution Approach 1:
The patent combines the electrical connection element and the mechanical holding element into a single integrated component. The holding element features both electrical contact surfaces for current conduction and form-locking elements (such as clamping jaws or retaining lugs) for mechanical attachment, eliminating the need for separate screw connections and reducing assembly complexity while maintaining mechanical stability.
Solution Approach 2:
The holding element is designed to perform multiple functions simultaneously: it provides electrical connection between the current sensor and the electrical connection element, provides mechanical support and stability, and ensures electrical insulation where needed. This multi-functional design replaces what would traditionally require multiple separate components including screws and insulation elements.
2Reliability
If additional electrical insulation is provided, then electrical insulation is improved, but device complexity increases
Solution Approach 1:
The holding element is designed with asymmetric electrical properties: certain regions are conductive to establish electrical connections, while other regions are made electrically insulating to prevent short circuits. This is achieved through material selection (e.g., insulating plastic with embedded conductive elements) or structural design (e.g., spatial separation of conductive and insulating regions), allowing the single component to provide both electrical connection and insulation without additional parts.
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 offers robust mechanical support and electrical insulation with reduced part and assembly costs, effectively securing current sensors and cables to vehicle batteries under various loads, including dynamic conditions, without the need for screws or additional insulation layers.
Implementation Method 1
the mechanical holding element is made from an elastic material, so that the mechanical holding element is designed to be robust with respect to dynamic mechanical loads such as oscillations, vibrations and impacts
Data Source
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AI summary
The invention relates to a mechanical retaining element (14) for holding a current sensor (6) having a first electrical contact element (28) for producing an electrical connection to a pole (4) of a vehicle battery, a second electrical contact element (28) for producing an electrical connection of an electrical connection element (38), and a current sensor (32) on the pole (4) of the vehicle battery, said current sensor electrically connected in series between the first and the second contact element (28), comprising: - a first positive-locking element (50) acting in a positive-locking direction (58) in order to receive a corresponding counterpart (30) on the pole (4) of the vehicle battery in a positive-locking manner and - a second positive-locking element (52) acting in opposition to the positive-locking direction (58) in order to receive a corresponding counterpart (44) on the electrical connection element (38) in a positive-locking manner.