Captured Busbar HV Header Sealing Against Moisture Intrusion
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Solution Overview
Problem
Current systems for rechargeable energy storage systems (RESS) connectors fail to adequately prevent moisture intrusion, particularly in high voltage applications, despite the use of face seals at HV header mounting bolts.
Innovation Solution
A housing with integral snorkels and O-rings, combined with a press-in-place seal and third-hand features, provides a comprehensive water-resistant protection system for RESS connectors, ensuring fluid-tight integrity and secure mounting to battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If face seals are used at HV header mounting bolts, then some water resistance is achieved, but moisture intrusion is not adequately prevented
Solution Approach 1:
The patent combines multiple sealing mechanisms (face seals at mounting bolts, O-rings on busbars, and a press-in-place seal at the housing perimeter) into an integrated sealing system. This merging of multiple sealing approaches creates comprehensive protection that prevents moisture intrusion through all potential entry points, resolving the inadequacy of using face seals alone.
Solution Approach 2:
The sealing system is segmented into multiple independent sealing zones: face seals at bolt locations, O-rings on individual busbars, and a perimeter seal at the housing. Each segment addresses specific vulnerability points, and together they create complete protection against moisture intrusion that cannot be achieved by a single sealing method.
2Object-affected harmful factors
If a sealed housing structure is implemented, then moisture protection is improved, but assembly complexity increases
Solution Approach 1:
The busbars are pre-assembled with O-rings attached to them before insertion into the housing. This preliminary action ensures proper sealing positioning is achieved automatically during assembly, eliminating the need for complex separate sealing operations and reducing overall assembly complexity while maintaining effective moisture protection.
Solution Approach 2:
The press-in-place seal automatically engages and seals the perimeter gap between the housing and battery pack wall through the insertion force itself. The act of inserting the housing into the battery pack creates the sealing action, eliminating the need for separate sealing steps or additional fastening operations for the seal.
3Reliability
If multiple sealing components are added, then moisture protection is enhanced, but manufacturing cost increases
Solution Approach 1:
The patent uses thin film O-rings made of elastomeric material that provide effective sealing with minimal material usage. These flexible seals conform to the mating surfaces and create reliable fluid-tight barriers without requiring thick or expensive sealing components, maintaining cost-effectiveness while enhancing protection.
Solution Approach 2:
The O-rings are simple, inexpensive elastomeric components that can be easily replaced if needed. Their low individual cost allows the design to incorporate multiple O-rings on different busbars without significantly increasing overall manufacturing cost, while providing comprehensive sealing coverage.
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 effectively prevents moisture intrusion into RESS connectors by creating a sealed geometry that protects high voltage headers from both external and internal liquid ingress, enhancing assembly efficiency and safety.
Implementation Method 1
a first biasing member defining the leading portion of the first third-hand feature elastically displaces in a first outward direction to capture the first biasing member against an outer facing surface of the end wall
Implementation Method 2
a press-in-place (PIP) seal is located proximate to perimeter wall of the housing mitigating against fluid intrusion into an inner cavity of the housing when the housing is pressed into contact with a housing wall of the vehicle battery pack
Implementation Method 3
Multiple face seals, including a first face seal, a second face seal, a third face seal and a fourth face seal create a fluid boundary seal about a perimeter of individual ones of the first threaded insert, the second threaded insert, the third threaded insert and the fourth threaded insert
Implementation Method 4
a first O-ring is located on an outer wall of the second cylindrical busbar and a second O-ring is located on the outer wall of the second cylindrical busbar, the first O-ring and the second O-ring mitigate against fluid intrusion into an inner cavity of the housing
Data Source
AI summary
A vehicle water resistant protection assembly includes a vehicle battery pack having an outer wall and an inner compartment. A rechargeable energy storage system (RESS) connector assembly includes a housing mounted within the inner compartment to an outer wall interior facing surface. An external adapter mounted to an outer wall exterior facing surface is in communication with the RESS connector assembly through the outer wall. A first cylindrical busbar and a second cylindrical busbar are disposed within the housing. A first snorkel and a second snorkel defining integral extensions of the housing have the first cylindrical busbar extending through and outward from the housing via the first snorkel and the second cylindrical busbar extending through and outward from the housing via the second snorkel. At least one O-ring is positioned on the second cylindrical busbar to mitigate against a fluid intruding into an inner cavity of the housing.