Battery Module Connector With Removable Contact Protection
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Solution Overview
Problem
Existing module connectors face challenges in providing safe contact protection while maintaining low electrical contact resistance, particularly in high-voltage applications like traction batteries, where voltage increases with module connection and high currents flow, leading to potential voltage flashovers and increased power loss.
Innovation Solution
A connector design featuring a first connecting element with a shaft and collar, incorporating a contact protection element with a dome-shaped structure that secures a fastening element against unintentional contact, allowing for non-positive and positive connections with low contact resistance by using a profiled inner lateral surface to hold the fastening element in place and enable easy removal after assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective pins are used to protect the tips of fastening elements, then contact protection is provided, but the contact surface area is limited and contact resistance increases
Solution Approach 1:
The connector is divided into separate functional components: a protective cover that can be detached after assembly, and the main connecting elements. This segmentation allows the contact surface to be maximized in the main body while the protective function is provided by a separate element that doesn't interfere with the contact area.
Solution Approach 2:
The protective cover is provided in advance during the assembly process to ensure contact protection before the connection is made. After the fastening elements are securely connected, the protective cover is removed, allowing the full contact surface to be utilized for optimal electrical connection.
2Loss of energy
If the contact surface is enlarged to reduce contact resistance, then power loss decreases, but contact protection becomes compromised due to larger gap requirements
Solution Approach 1:
The protective function is separated from the contact function. The protective cover provides the necessary protection during assembly, while the main connecting elements provide the enlarged contact surface for low resistance. This separation allows both requirements to be satisfied simultaneously without compromise.
Solution Approach 2:
The protective cover acts as an intermediary element during the assembly process. It provides the necessary contact protection while allowing the main connecting elements to achieve their full contact surface area. Once assembly is complete, the intermediary protective cover is removed, allowing optimal electrical contact.
3Reliability
If protective covers are used on screw elements, then contact protection is improved, but screwing operation becomes impossible
Solution Approach 1:
The protective function is segmented into a separate removable cover rather than being integrated into the screw element itself. This allows the screw element to remain fully accessible and operable, while the protective cover provides necessary protection during assembly and can be easily removed when no longer needed.
4Loss of energy
If the gap on the insulating housing is reduced to allow larger contact region, then contact resistance decreases, but test finger contact protection becomes compromised
Solution Approach 1:
The protective cover is provided in advance during assembly to ensure test finger protection is maintained. This preliminary protective measure allows the housing gap to be minimized for optimal contact area, while the protective cover ensures safety during the assembly process before the connection is complete.
Data Source
AI summary
Connector, in particular module connector, in particular battery module connector, in particular for vehicles with an electric drive, comprising a first connecting element which can be electrically conductively connected to a second connecting element, the first connecting element having a socket with an axially extending shaft with a through-opening and a radially extending collar, and wherein a screw element and a contact protection element are arranged on the first connecting element, wherein the contact protection element is arranged on the side facing the collar.