Traction Battery Housing Step Configuration for Connector Protection
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Solution Overview
Problem
Existing support structures for vehicle traction batteries lack effective protection and organization of connectors, which can lead to accidental damage and inefficient integration with other vehicle components, affecting the overall performance and safety of battery systems.
Innovation Solution
A housing design with a step configuration at the lateral end, featuring a ledge and recessed face, that limits the travel of objects and provides defined openings for various connectors such as battery control interface, accessory, and high-voltage connectors, ensuring secure and organized connections to power electronics modules and other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If connectors are allowed to extend freely from the housing, then ease of connection is improved, but vulnerability to accidental damage increases
Solution Approach 1:
The patent introduces a step configuration with a ledge that extends perpendicular to the recessed face, creating a three-dimensional protective structure. This ledge forms a physical barrier that limits the travel of objects attempting to impact the connectors, thereby protecting them from accidental damage while still allowing connectors to extend outward for connection purposes.
Solution Approach 2:
The housing structure incorporates a localized protective feature (the ledge) specifically at the region where connectors extend. This creates different functional zones: the recessed face area allows connector extension for connectivity, while the ledge provides localized protection against damage. This selective application of protection maintains ease of connection while reducing vulnerability.
2Adaptability or versatility
If connectors are extended through the housing, then electrical connection capability is improved, but protection from external factors deteriorates
Solution Approach 1:
The ledge extends in a direction perpendicular to the recessed face, creating a multi-dimensional protective enclosure. This three-dimensional structure allows connectors to extend through the housing for electrical connection while the ledge forms a protective barrier that shields them from external harmful factors such as impact, moisture, or contamination.
Solution Approach 2:
The ledge acts as an intermediary protective structure between the external environment and the connectors. It provides a physical barrier that protects connectors from external harmful factors while still allowing them to extend outward to establish electrical connections with other components.
3Reliability
If a step configuration with ledge is added to the housing, then connector protection is improved, but housing complexity increases
Solution Approach 1:
The housing is segmented into distinct functional regions: the recessed face that allows connector extension and the ledge that provides protection. This segmentation creates a modular structure where each element serves a specific purpose, making the overall design more manageable despite the increased complexity.
Solution Approach 2:
The step configuration with ledge is applied locally only at the specific region where connectors extend from the housing, rather than complicating the entire housing structure. This localized approach minimizes the increase in overall housing complexity while providing targeted protection where it is most needed.
Data Source
AI summary
A vehicle traction battery assembly is provided which may include a housing, a battery system supported within the housing, and a connector electrically connected with the system and extending through and away from the recessed face into a region normal to the recessed face and adjacent to the ledge such that the ledge limits travel of objects into the region impacting the lateral end. The lateral end may have a step configuration defined by the ledge and the recessed face. The housing may also include a middle face extending between the ledge face and recessed face, opposing side faces, and a lower face. The connector may be a battery control interface connector, an accessory connector, or a high-voltage connector.