Overmolded Battery Terminal Posts Prevent Leakage
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Solution Overview
Problem
Traditional battery module configurations face challenges with complicated electrical coupling between electrochemical cells and terminal posts, leading to electrolyte leakage and increased material costs due to welding requirements, which complicates manufacturing and reduces energy density.
Innovation Solution
The integration of major terminals and bus bars with similar or dissimilar materials, where the bus bars envelop the terminal posts without welding, and the assembly is overmolded with a plastic base for secure electrical connection and leakage prevention, using a plastic housing with a receptacle and weld to seal the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical coupling between electrochemical cells and terminal posts is used, then electrical connectivity is achieved, but electrolyte leakage occurs and manufacturing complexity increases due to welding requirements
Solution Approach 1:
The patent introduces a plastic base as an intermediary component between the electrochemical cells and terminal posts. This plastic base integrates the electrical coupling function while providing a sealed structure that prevents electrolyte leakage, eliminating the need for separate welding operations and reducing manufacturing complexity
Solution Approach 2:
The patent employs composite material construction by combining plastic (polymer) material with electrical conductive elements. The plastic base serves both structural and electrical functions, creating a composite assembly that achieves reliable electrical connectivity while preventing electrolyte leakage through the inherent properties of the plastic material
2Reliability
If welding is used to connect terminal posts and bus bars, then electrical connection is achieved, but material costs increase and manufacturing complexity increases
Solution Approach 1:
The patent replaces the welding (thermal/mechanical) system with a mechanical assembly system using the plastic base. The terminal posts and bus bars are mechanically integrated into the plastic base through molded-in features, eliminating the need for welding operations and reducing manufacturing complexity while maintaining reliable electrical connection
Solution Approach 2:
The patent merges multiple functions into the plastic base component: structural support, electrical insulation, electrical connection facilitation, and sealing. By combining these functions into a single integrated component, the need for separate welding operations is eliminated, reducing manufacturing complexity and material costs
3Reliability
If complicated electrical coupling components are used, then electrical connectivity is achieved, but energy density decreases due to increased material usage
Solution Approach 1:
The patent merges multiple components (terminal post, bus bar, insulator, and sealing elements) into a single integrated plastic base assembly. This consolidation reduces the total quantity of materials required while maintaining effective electrical connectivity, thereby improving energy density
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
This solution enhances the integration of terminal posts within the battery module, reducing material costs, simplifying manufacturing, and improving energy density by eliminating the need for welding and preventing electrolyte leakage, while maintaining effective electrical connectivity.
Implementation Method 1
wherein a portion of the electrical assembly is overmolded by the plastic base
Implementation Method 2
wherein the battery module comprises a weld between the lip of the plastic base and the surface of the plastic housing
Data Source
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AI summary
A battery module includes a terminal block assembly having an electrical assembly and a plastic base. The electrical assembly includes a terminal post and a bus bar coupled with the terminal post. A portion of the electrical assembly is overmolded by the plastic base, and the portion includes at least part of a terminal post base that extends outward from a central axis of a post portion of the terminal post. The battery module also includes a plastic housing having a receptacle configured to receive the plastic base of the terminal block assembly.