Integrated Battery Connector with Monolithic Sealing
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Solution Overview
Problem
Existing connector devices for batteries in electric vehicles are complex to mount, lack reliable sealing against liquids and gases, and require separate connectors for different electrical connections, leading to increased assembly effort and potential leakage.
Innovation Solution
A connector device with integrated plug contours and busbars, manufactured through injection molding, provides a monolithic and sealed connection system with a single sealing element, allowing for compact and efficient mounting on the battery housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate connectors are used for different electrical connections, then each connection can be independently designed, but the assembly complexity and number of mounting steps increase
Solution Approach 1:
The patent combines multiple separate connectors into a single integrated connector device that includes multiple plug contours and busbars. This merging approach reduces the number of separate components that need to be mounted, simplifying assembly while maintaining the ability to provide multiple independent electrical connections. The connector device is mounted in a single step on the battery housing, eliminating the need for multiple separate mounting operations.
Solution Approach 2:
The connector device serves multiple functions simultaneously by providing several plug contours that can accommodate different types of connectors (charging device, pressure equalization device, low-voltage consumers). This multi-functional design allows a single component to replace multiple specialized connectors, reducing assembly complexity while maintaining design flexibility for different connection types.
2Adaptability or versatility
If multiple separate connectors are mounted on the battery housing, then each connection can be established independently, but the number of sealing elements required increases
Solution Approach 1:
The patent integrates multiple connector functions into a single connector device that uses only one sealing element. This approach maintains the independence of different electrical connections through separate plug contours while eliminating the need for multiple sealing elements, thereby improving sealing reliability and reducing potential leakage points.
3Adaptability or versatility
If multiple separate connectors are used, then each connection can be optimized for its specific function, but the space required on the battery housing increases
Solution Approach 1:
The patent consolidates multiple connectors into a single integrated connector device with multiple plug contours arranged in a compact configuration. This merging allows optimized connections for different functions (charging, pressure equalization, low-voltage) while occupying significantly less space on the battery housing compared to multiple separate connectors.
4Ease of operation
If separate connectors are mounted individually, then each connector can be installed independently, but the total assembly time and effort increase
Solution Approach 1:
The patent combines multiple connectors into a single connector device that can be mounted in one operation. This approach maintains installation independence for each electrical connection through modular plug contours while dramatically improving assembly efficiency by reducing the number of mounting steps from multiple separate operations to a single mounting action.
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
The solution simplifies assembly, ensures reliable liquid- and gas-tight sealing, and reduces the number of required sealing elements, while enabling space-saving and efficient electrical connections for various devices.
Implementation Method 1
manufactured through injection molding
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a connector device (14) for a battery (4) having a battery housing (6), in particular of an electrically powered motor vehicle (2), with a connector base body (46) having at least two integrally formed plug contours (48, 50, 52, 54, 56), each of which is provided for receiving a plug counterpart contour (26a, 30a, 34a, 38c, 38d, 42a) of a plug element (26, 30, 34, 38a, 38b, 42), with a number of busbars (58, 60, 62, 64, 66) incorporated into the connector base body (46), each of which has at least two connection contacts (58a, 58b, 58c, 60a, 60b, 62a, 62b, 64a, 64b, 66a, 66b), of each has one connection contact (58b, 60b, 62b, 64b, 66b) for internal electrical connection to a battery terminal (10, 12), and the other connection contact (58a, 58c, 60a, 62a, 64a, 66a) is located in one of the plug-in contours (48, 50, 52, 54,56) for external plug connection with the associated plug element (26, 30, 34, 38a, 38b, 42), and with a sealing element (86) for liquid- and gas-tight sealing of the connection base body (46) to the battery housing (6). Furthermore, the invention relates to a battery (4) with such a plug device (14) and a motor vehicle (2) with such a battery (4).