Battery Electrical Box Connector Layout for Compact Overcurrent Protection
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Solution Overview
Problem
Current electrical connections between battery output terminals and electrical boxes in new energy vehicles require significant space due to the use of long electrically conductive structures, leading to increased size and cost.
Innovation Solution
Integration of the first connector, current interrupter, and switch into a compact module within the electrical box, eliminating the need for a long conductive structure and enhancing space utilization, while ensuring electrical safety through current interruption and preventing excessive charging or discharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a long electrically conductive structure (such as a copper bar) is used to connect the battery output terminal to the electrical box, then the electrical connection is reliable, but the space occupancy increases significantly
Solution Approach 1:
The patent merges the first connector and the electrical box into an integrated module. The first connector is fixed to the box body with its terminals electrically connected to the current interrupter and switch inside the box, eliminating the need for a long separate conductive structure and significantly reducing space occupancy while maintaining reliable electrical connection
Solution Approach 2:
The patent introduces a current interrupter as an intermediary component between the battery output terminal and the electrical box. This current interrupter serves as a mediator that can interrupt current flow when it reaches a predetermined value, providing safety functionality while enabling a more compact connection structure
2Reliability
If a long electrically conductive structure is used for connection, then the electrical safety can be ensured, but the structural compactness deteriorates
Solution Approach 1:
The first connector is integrated into the electrical box structure, with the connector body fixed to the box body and terminals internally connected to safety components. This merging achieves both electrical safety through proper component integration and improved structural compactness by eliminating external long conductive structures
Solution Approach 2:
The first connector is nested within the electrical box structure, with the connector accommodated in a first opening of the box body. The connector's terminals are electrically connected to components inside the box, creating a nested arrangement that enhances structural compactness while maintaining safety functions
3Volume of moving object
If the first connector is integrated into the electrical box module, then the space utilization is improved, but the device complexity increases
Solution Approach 1:
The first connector is merged with the electrical box into a single module, improving space utilization. The connector is fixed to the box body with terminals connected to existing internal components (current interrupter and switch), which manages the integration complexity by utilizing existing structural elements rather than requiring entirely new complex assemblies
Data Source
AI summary
An electrical box for a battery comprising a battery cell includes a box body, a current interrupter, a connector, and a switch. The current interrupter is provided in the box body and configured to be disconnected in response to overcurrent. The connector is configured to output electric energy of the battery. The switch is arranged in the box body and configured to control connection or disconnection between the battery cell and the connector. The connector is fixed to the box body, and the connector includes a first terminal and a second terminal that are configured to output the electric energy of the battery. The first terminal is electrically connected to the current interrupter, and the second terminal is electrically connected to the switch.