Battery Connector Segmentation for Maintenance Access

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Solution Overview

Problem

The existing connector systems for high-voltage battery assemblies in electric vehicles are inconvenient to maintain due to the need to completely disassemble the battery case and internal terminals to replace a damaged electrical connector, which is prone to damage from handling and external impacts.

Innovation Solution

A connector apparatus comprising a connector block assembly with electrodes and a header assembly that allows for the replacement of external terminals without separating the battery case from the vehicle body, featuring a block body with conductive and non-conductive components, and a shield shell for electromagnetic shielding, enabling easy maintenance by exposing only the header assembly for connection and replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the electrical connector protrudes from the battery case exterior for connection, then it enables external electrical connection, but it becomes vulnerable to damage from careless handling and external impacts

Engineering Contradiction:

Improveexternal connection capabilityVSAvoidconnector damage resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The connector is divided into two separable parts: the header assembly (with terminals) that remains inside the battery case, and the electrical connector (protruding part) that can be independently removed. This segmentation allows the vulnerable protruding connector to be replaced without affecting the internal terminal structure, reducing damage risk while maintaining external connection capability.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If the internal terminals are integrated with the battery case, then structural stability is improved, but replacement of damaged connectors requires complete disassembly of the battery case

Engineering Contradiction:

Improvebattery case structural stabilityVSAvoidconnector replacement convenience

Core Design Contradiction:

Stability of the object's compositionVSEase of repair

Solution Approach 1:

The connector system is segmented into the header assembly (integrated with battery case) and the electrical connector (separable). The header assembly includes mounting structures that maintain structural stability when integrated with the battery case, while the separable electrical connector can be independently replaced, enabling easy repair without complete disassembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrical connector is extracted as a separable component from the integrated connector system. The header assembly remains mounted in the battery case with mounting protrusions fitting into mounting holes, while the electrical connector can be independently removed and replaced, enabling maintenance without complete battery case disassembly.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If the connector system requires complete separation of battery case from vehicle body for maintenance, then internal terminal protection is improved, but maintenance time and complexity increase significantly

Engineering Contradiction:

Improveinternal terminal protectionVSAvoidmaintenance time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The connector system is divided into the header assembly (remaining in battery case) and the electrical connector (externally replaceable). This segmentation allows replacement of the damaged electrical connector without separating the battery case from the vehicle body, significantly reducing maintenance time while the header assembly continues to protect internal terminals.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrical connector is extracted as a separately replaceable component. The header assembly remains mounted in the battery case with its mounting structure (protrusions fitting into holes), allowing the electrical connector to be independently accessed and replaced without removing the battery case from the vehicle body, thus protecting internal terminals while minimizing maintenance time.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Facilitates the replacement of damaged electrical connectors without disassembling the battery case, enhancing maintenance efficiency and reducing the risk of further damage during handling and impacts, while maintaining electrical connectivity and providing electromagnetic shielding.

Implementation Method 1

a shield shell inserted into the header housing to surround the first and second terminals

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Data Source

PatentUS11489272B2Connector apparatus for a battery

Publication Date: 2022.11.01 HYUNDAI MOTOR CO LTD

AI summary

A connector apparatus for a battery includes: a connector block assembly mounted in a battery case of a battery assembly, and including first and second electrodes facing the interior of the battery case; and a header assembly releasably mounted to the connector block assembly, and including first and second terminals connected to the first and second electrodes, respectively. The header assembly is exposed to the exterior of the battery case and the first and second terminals are electrically connected to terminals of a mating connector, respectively.