Staple Terminal Electrical Connection Device for Traction Battery
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Solution Overview
Problem
The assembly of lithium-ion batteries for electric and hybrid vehicles is complex and time-consuming due to the high voltage levels, requiring numerous small screws that are difficult to handle safely, leading to a high risk of assembly faults and contact errors.
Innovation Solution
An electrical connection device with a staple terminal and a molded resin frame that exerts a bearing force to maintain the terminal in electrical contact, allowing for easier assembly and reduced tool usage, featuring a staple lug with claws that grip into a threaded orifice for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous small screws are used to connect modules in high voltage batteries, then the electrical connection reliability is improved, but the assembly complexity and time increase significantly
Solution Approach 1:
The patent combines multiple screw connections into a single integrated connection element. The terminal unit integrates the voltage detection terminal and the power connection terminal into one unified structure that connects to the module connector simultaneously, eliminating the need for separate small screws while maintaining electrical connection reliability.
Solution Approach 2:
The terminal unit serves multiple functions: it provides voltage detection through the voltage detection terminal, establishes power connection through the power connection terminal, and provides mechanical support. This multi-functional design replaces numerous specialized small screws with a single universal connection element.
2Reliability
If numerous small screws are used for assembly, then the electrical connection reliability is improved, but the assembly time is excessive
Solution Approach 1:
Multiple connection operations are merged into a single assembly action. The terminal unit is installed in one operation that simultaneously establishes both voltage detection connection and power connection, dramatically reducing assembly time while maintaining connection reliability.
Solution Approach 2:
The terminal unit is pre-assembled with all necessary connection elements integrated before installation. This preliminary integration of voltage detection terminal and power connection terminal allows for rapid single-step installation without requiring multiple separate assembly operations.
3Area of stationary object
If small screws are used for connection, then the contact surface area is sufficient, but the handling difficulty increases due to safety requirements
Solution Approach 1:
The patent merges multiple small handling operations into a single handling operation. Instead of requiring operators to handle numerous small screws individually (which is difficult with insulating rubber gloves), the terminal unit is handled as one larger, more manageable component that provides sufficient contact surface area.
Solution Approach 2:
The terminal unit acts as an intermediary that bridges the gap between safety requirements and handling ease. It provides the necessary contact surface area for reliable electrical connection while its larger size makes it suitable for safe handling with insulating rubber gloves, unlike the small screws it replaces.
Data Source
Figure 1
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AI summary
Device for the fast fitting of electrical connections, in particular on a traction battery. The present invention relates to an electrical connection device for linking a conducting wire to an earth conductor comprising a tapped orifice. The device comprises a lug to which the wire is linked, the lug comprising at least two fastening elements and being able to pass alternately from a free configuration to a configuration fastened in the tapping of the orifice. The device also comprises a bearing element able to be fixed firmly to the earth conductor, in such a way that it simultaneously exerts a bearing force on the lug, said bearing force holding the lug in its fastening configuration. Application: traction batteries.