Module Connector Touch Protection via Nested Insulated Collar
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Solution Overview
Problem
Existing module connectors for vehicle batteries with electric drives pose a risk to users due to high voltages and currents, and current configurations are complex and difficult to assemble.
Innovation Solution
A module connector design featuring two connection parts with electrically insulated collars and protection pins, where the protection pins are formed by the peaks of affixing elements, providing touch protection and allowing for secure, space-saving assembly with a dual-function affixing mechanism, and optional features like coding for correct angular positioning and materials with low resistance for efficient current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate protection components are used, then touch protection is achieved, but device complexity increases
Solution Approach 1:
The patent combines multiple protection functions into a single integrated protective cover that simultaneously provides touch protection, mechanical protection, and electrical insulation. This merging of functions reduces the number of separate components while maintaining comprehensive protection capabilities.
Solution Approach 2:
The protective cover is designed to perform multiple functions: it acts as a physical barrier against finger contact, provides mechanical protection for internal components, and offers electrical insulation. This multi-functionality eliminates the need for separate dedicated components for each protection type.
2Reliability
If multiple separate components are used for protection, then comprehensive protection is achieved, but ease of manufacture decreases
Solution Approach 1:
By integrating touch protection, mechanical protection, and electrical insulation into a single protective cover component, the manufacturing process is simplified. Instead of assembling multiple separate protection components, manufacturers can produce and install one integrated unit, reducing assembly steps and potential errors.
3Reliability
If protection components extend beyond current bridge, then touch protection is improved, but volume increases
Solution Approach 1:
The protective cover is designed to nest around the current bridge and other internal components, extending only as far as necessary to provide effective touch protection. This nested configuration provides maximum protection with minimum volume increase.
Solution Approach 2:
The protective cover utilizes the radial dimension to provide protection by extending outward from the current bridge, rather than increasing length in the connection direction. This dimensional approach provides comprehensive protection while maintaining a compact overall connector size.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention shows a module connector (1), in particular for batteries (2) of vehicles with an electric drive, with two connection parts (3, 31, 32) which can be connected to one another in an electrically conductive manner and to which a conductor element (5) can be attached at each conductor point (4), and which each have a mutually compatible affixing element (6), wherein each connection part (3, 31, 32), at its connection side (7) oriented towards the respective other connection part (3, 31, 32), is provided with a touch protection (8) having an outer, electrically insulated collar (9) and an electrically insulated protection pin (10) which is surrounded by the collar, wherein a current bridge (11) which electrically connects the two conductor points (4) and which the collar (9) and protection pin (10) project beyond is located at at least one connection part (3, 31, 32) between the collar (9) and protection pin (10).