Battery Pack Connector With Insulating Jacket For Housing Wall
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing battery pack fabrication process is hindered by the difficulty in connecting battery modules and busbars due to limited accessibility of connection points, which restricts the degree of automation and complicates the wiring process, especially when passing through holes in the housing walls.
Innovation Solution
A battery pack design featuring a connector with an electrically conducting body and an insulating jacket, positioned within through-holes in the housing walls, allowing for easy connection and disconnection of wiring from both sides, facilitating automation and simplifying the assembly process. The connector includes slope-aligned split-ribs for secure positioning and alignment, ensuring reliable electrical conductivity and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If wiring directly connects battery modules through housing walls, then electrical connectivity is achieved, but accessibility of connection points is limited and automation is restricted
Solution Approach 1:
The connector is divided into multiple parts: a first connecting body with a first connection point for battery module connection, and a second connecting body with a second connection point for busbar connection. This segmentation allows each connection point to be independently accessible from appropriate sides of the housing wall, enabling automated wiring processes while maintaining electrical connectivity.
2Ease of manufacture
If wiring passes through holes in housing walls, then electrical paths are established, but the process becomes complex and difficult to automate
Solution Approach 1:
The connector acts as an intermediary component that facilitates electrical connection between battery modules and busbars through the housing wall. The connector's dual-body design with connection points on opposite sides eliminates the need for complex wiring routing through the wall, simplifying the manufacturing process and enabling automated assembly.
3Ease of operation
If connection points are positioned for direct wiring, then electrical connectivity is achieved, but accessibility from both sides of the wall is restricted
Solution Approach 1:
The connector extends in the dimensional direction perpendicular to the housing wall, with connection points positioned on opposite sides of the wall. This spatial arrangement allows wiring to access connection points from both sides of the housing without compromising electrical conductivity, as each connection point maintains direct electrical contact with its respective component.
Data Source
Figure 1
Figure 2
Figure 3A~3D
AI summary
The present invention provides a battery pack comprising a one or more battery modules, each including a plurality of secondary battery cells; a housing for accommodation of the one or more battery modules, the housing including an exterior wall and one or more inner walls; and a wiring for interconnecting the battery modules among each other and/or with one or more busbars, wherein the walls of the housing include at least one through-hole where the wiring is passing through. The battery pack is characterized in that a connector is placed within the through-hole. The connector includes an electrically conducting body and a jacket made of an electrically insulating material and surrounding an outer surface of the conducting body. The conducting body is connectable with the wiring from both sides of the wall.