Electric Connector Attachment Structure for Low Battery Pack Height
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Solution Overview
Problem
In electric vehicles with low ground clearance and battery packs of low height, existing attachment structures for electric connectors face challenges in maintaining connector inclination and tray capacity, leading to increased tray size and cable length requirements.
Innovation Solution
An electric-connector attachment structure featuring an inclined portion on the tray or cover that extends across a horizontal plane, with a protruding portion between the joint surface and the inclined portion, allowing connector attachment without reducing the inclination angle, and including facing portions for protection, which prevents tray size increase and ensures adequate cable length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the height of the battery pack is reduced to accommodate low ground clearance, then the battery pack can be installed in vehicles with low ground clearance, but the inclined portion must be reduced or flattened which increases the area occupied on the tray
Solution Approach 1:
The inclined portion is extended into the third dimension by making it protrude from the horizontal plane passing through the joint surface. This vertical protrusion allows the inclined portion to maintain its inclination angle while occupying less horizontal area on the tray, effectively resolving the contradiction between reduced battery pack height and tray area occupation.
2Length of stationary object
If the inclination angle of the inclined portion is reduced to attach the connector at low battery pack height, then the connector can be attached, but the electrical cable must be connected to a lower part which requires longer cable length
Solution Approach 1:
By extending the inclined portion vertically from the horizontal plane, the connector can be positioned at an optimal height without reducing the inclination angle. This maintains the cable routing path at a higher position, avoiding the need for excessively long cables while still accommodating low battery pack height requirements.
Solution Approach 2:
The inclined portion is localized to a specific region protruding from the horizontal plane, allowing the connector to be attached at a precise location that optimizes cable length. This localized structural modification enables independent optimization of connector positioning without affecting the entire tray geometry.
3Reliability
If the inclined portion is extended to maintain inclination angle, then connector attachment is improved, but the tray capacity (volume) is reduced
Solution Approach 1:
The tray structure is segmented into the main horizontal tray body and the separate protruding inclined portion. This segmentation allows the inclined portion to be optimized for connector attachment while the main tray body maintains its full capacity for battery accommodation, minimizing the impact on overall tray volume.
Solution Approach 2:
The inclined portion utilizes vertical space by protruding from the horizontal plane, effectively using the third dimension to provide connector attachment functionality without significantly encroaching on the horizontal storage capacity of the tray.
Data Source
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AI summary
To provide an electric-connector attachment structure of a battery pack for an electric vehicle, which can attach an electric connector to a battery pack even when the height of the battery pack for an electric-vehicle is set low, the electric-connector attachment structure includes: a battery pack 3 for an electric vehicle including a tray 4 of a box-like shape which accommodates a battery and has an opening on an upper side, and a cover 5 of a box-like shape having an opening on a lower side, the tray 4 and the cover 5 being joined at a horizontal plane; and an electric connector 6 to which an electrical cable 61 is connected. It further includes an inclined portion 441, 551 to which the electric connector 6 is connected, disposed at an inner side of the battery pack 3 with respect to a joint surface 461 at which the tray 4 and the cover 5 are joined, extending over lower and upper regions across the horizontal plane H passing through the joint surface 461; and a protruding portion 443, 553 disposed between the joint surface 461 and the inclined portion 441, 551 so as to protrude from the horizontal plane passing through the joint surface 461 in a direction opposite to the electric connector 6. The inclined portion 441, 551 is formed so as to be continuous from the protruding portion 443, 553.