Battery Module Connector Barrel Routing and Protection
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Solution Overview
Problem
Existing battery modules face challenges in manufacturing and integrating components that support and guide electrical circuitry within limited spaces, making it difficult to provide adequate support and protection for the circuitry while ensuring proper integration with the housing.
Innovation Solution
A connector barrel is designed within the battery module housing to guide and route electrical circuitry, including low voltage signal and vehicle control module connectors, with a hollow conduit configuration and flexible ribs for secure fit and ergonomic manipulation, allowing for efficient communication between the battery module and vehicle control module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector barrel is added to guide and protect electrical circuitry, then the reliability and protection of electrical connections is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The connector barrel is integrated with the battery module housing as a single unified structure, eliminating the need for separate mounting brackets or support components. This merging approach provides electrical circuitry guidance and protection while avoiding the complexity of multiple discrete parts and their associated assembly steps.
Solution Approach 2:
The connector barrel serves multiple functions simultaneously: it guides electrical circuitry into proper alignment, protects connectors from environmental factors, provides structural support, and enables secure mating of electrical connections. This multi-functionality reduces the need for additional specialized components.
2Reliability
If the connector barrel is designed with secure fit features like flexible ribs, then the connection reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The flexible ribs are designed with specific geometric parameters including thickness, length, and curvature radius that allow them to flex within defined limits. These parameter optimizations enable the ribs to accommodate normal dimensional variations from manufacturing tolerances while still providing secure connection forces.
Solution Approach 2:
The flexible ribs incorporate elastic deformation capability, transitioning from rigid to flexible behavior under load. This dynamic characteristic allows the connector barrel to adapt to slight misalignments and maintain reliable electrical connections despite variations in manufacturing precision.
Data Source
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AI summary
The present disclosure relates to a battery module. The battery module includes a housing defined by one or more walls. A wall of the housing includes an opening configured to create a passageway between an interior of the housing and an exterior of the housing. The battery module includes a connector barrel disposed within the opening. The connector barrel is a hollow conduit with a first open end opposite a second open end, and the connector barrel is configured to receive a low voltage signal connector through the first open end and a vehicle control module connector through the second open end. An external surface of the connector barrel includes a pair of protrusions configured to enable intimate contact between the wall of the housing and the connector barrel.