Battery Module Connector Barrel With Sealing Flange
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Solution Overview
Problem
Existing battery modules have complex and cumbersome architectures for supporting electrical circuitry, which hinders efficient communication between the battery module and external devices.
Innovation Solution
A battery module with a connector barrel having a flange and energy concentrator ridges, which is ultrasonically welded or heat-treated to securely attach to the housing, facilitating the connection of internal and external electrical connectors and improving the packaging and sealing of the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional architectures are used to support electrical circuitry in battery modules, then the structural integrity and support are maintained, but the architecture becomes complex and cumbersome, hindering efficient communication between the battery module and external devices
Solution Approach 1:
The connector is divided into a barrel portion and a flange portion that are separately molded and then joined together. This segmentation allows each part to be optimized independently - the barrel for electrical connection functionality and the flange for sealing and mounting - thereby reducing overall complexity while improving communication efficiency
Solution Approach 2:
The barrel is inserted into and nested within the housing structure, with the flange extending outward to seal against the housing wall. This nested arrangement integrates the connector within the existing battery module architecture without adding external complexity, while maintaining efficient electrical pathways
2Ease of operation
If a connector barrel is added to facilitate electrical communication, then the efficiency of communication improves, but the part count and manufacturing complexity increase
Solution Approach 1:
The barrel and flange are combined into a single integrated connector component through ultrasonic welding. This merging reduces the part count compared to having separate barrel and flange components that would require additional fastening hardware, while still providing both electrical communication functionality and sealing capability
Solution Approach 2:
The connector barrel serves multiple functions: it provides the electrical connection pathway, the flange provides sealing against the housing wall, and the integrated structure serves as a mounting feature. This multi-functionality eliminates the need for separate sealing elements and mounting hardware, reducing overall part count
3Reliability
If the connector barrel is securely attached to the housing, then the reliability of the connection improves, but the manufacturing process becomes more complex
Solution Approach 1:
The mechanical fastening system (screws, clips, or adhesives) is replaced with ultrasonic welding, which uses mechanical vibration to create a molecular bond between the flange and housing wall. This substitution provides superior connection reliability while actually simplifying the manufacturing process by eliminating the need for separate fastening operations
Solution Approach 2:
The attachment method transitions from mechanical (discrete fasteners) to thermal-mechanical (ultrasonic welding). By changing the fundamental attachment parameter from mechanical interlocking to molecular bonding through controlled vibration and heat, the process achieves higher reliability with a more integrated manufacturing step
4Reliability
If the flange is designed to seal against the housing wall, then the sealing performance improves, but the manufacturing precision requirements increase
Solution Approach 1:
The flange is designed with localized sealing features (such as gasket integrations or compliant material zones) at the specific interface with the housing wall, while the rest of the connector maintains rigid structural integrity. This local quality approach concentrates the sealing function at the critical interface, providing reliable sealing without requiring ultra-precise manufacturing across the entire connector
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 the manufacturing process, enhances the seal of the housing, reduces the part count, and effectively connects internal and external signal connectors, improving the overall efficiency of electrical communication within the battery module.
Implementation Method 1
the plurality of energy concentrator ridges are configured to facilitate ultrasonic welding of the flange to a wall of the battery module
Implementation Method 2
applying heat to cause local melting along an interface between the first surface of the flange and the wall, and cooling the interface such that the interface has a weld between the wall and the flange
Data Source
AI summary
The present disclosure is directed to a battery module having an outer housing configured to receive a plurality of electrochemical cells, in which the outer housing has a wall including an inner surface facing a cavity formed by the outer housing, an outer surface opposite to the inner surface, and an opening extending through the wall. The battery module also includes a connector barrel configured to be disposed in the opening of the wall, in which the connector barrel has a first open end, a second open end, and a body forming a hollow interior between the first open end and the second open end, in which the connector barrel has a flange disposed on the body and extending outwardly from the body, and in which the flange has a plurality of ridges configured to abut the wall.