Battery Module Signal Connector Actuation and Sealing
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Solution Overview
Problem
Existing battery module designs face challenges in accessing and securely coupling the signal connector to the housing cover, making it difficult to establish a reliable electrical connection with control modules, especially when sealing the module housing.
Innovation Solution
A battery module design that includes a signal connector configured to be actuated from a first position to a second position, with a vent port allowing access for a push device to direct it into engagement with the housing cover, and laser welding to secure the connector to the cover, ensuring accessibility and a secure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing cover is sealed to enclose the battery cells and electrical components, then the sealing and protection of internal components is improved, but the accessibility of the signal connector to the output connector deteriorates
Solution Approach 1:
The signal connector is designed with moveability relative to the housing cover, allowing it to transition between a first position (accessible through the vent port) and a second position (engaged with the housing cover). This dynamic positioning enables the connector to be accessible during assembly while maintaining a sealed enclosure during operation.
Solution Approach 2:
The housing cover is segmented with a vent port that provides selective access to the signal connector. This segmentation allows the connector to be accessible through the vent port for connection to the output connector while the rest of the housing cover remains sealed to protect internal components.
2Ease of manufacture
If the signal connector is positioned for easy access during assembly, then the ease of manufacture is improved, but the secure coupling to the housing cover deteriorates
Solution Approach 1:
The signal connector transitions from a first position (accessible for connection to output connector) to a second position (engaged with housing cover) after assembly. This dynamic movement ensures easy initial access for manufacturing while achieving secure coupling in the final position.
Solution Approach 2:
The signal connector is initially positioned in the first position to facilitate easy connection to the output connector during assembly. After this preliminary connection is made, the connector is then moved to and secured in the second position for reliable coupling to the housing cover.
3Reliability
If the housing cover is made opaque for protection, then the protection of internal components is improved, but the accessibility for laser welding deteriorates
Solution Approach 1:
The housing cover has different optical properties at different locations: it is opaque at most areas to protect internal components, but has a transparent portion at the vent port area to allow laser transmission for welding the signal connector while maintaining overall protection.
Solution Approach 2:
The transparent portion of the housing cover acts as an intermediary that allows laser energy to pass through to weld the signal connector to the housing cover, while the opaque portions maintain protection of internal components. This selective transparency enables both protection and manufacturability.
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
This design allows for efficient and secure coupling of the signal connector to the housing cover, enabling reliable communication between electrical components and control modules within the battery module, even after the housing is sealed.
Implementation Method 1
laser welding to secure the connector to the cover
Implementation Method 2
a surface of the signal connector contacts an inner surface of the housing cover when the signal connector is in the second position
Data Source
AI summary
The present disclosure relates to a battery module that includes a housing having a first opening configured to receive one or more battery cells and an electrical component, a housing cover configured to be disposed over the first opening to enclose the one or more battery cells and the electrical component in the housing, a signal connector disposed within the housing and electrically coupled to the electrical component, where the signal connector is configured to be actuated from a first position to a second position, and a vent port in alignment with the signal connector such that the signal connector is accessible to a push device passing through the vent port to facilitate directing the signal connector into the second position and toward a second opening of the housing cover when the housing cover is disposed over the first opening.