Battery Module Connector Barrel for Guided Connector Securement
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Solution Overview
Problem
There is a need for improved components within battery modules to support and guide electrical circuitry effectively within limited spaces, while providing necessary protection and integration with the housing, to enhance the performance and efficiency of battery systems in electric vehicles and other high-voltage applications.
Innovation Solution
A connector barrel with a hollow conduit and specific design features, such as a ridge and circumferential bumps, is integrated within the battery module housing to securely position and route electrical signal connectors, including low voltage and vehicle control module connectors, ensuring proper alignment and securement, and optionally incorporating flexible teeth for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate components are used for supporting electrical circuitry within battery module housing, then the electrical circuitry can be supported, but the device complexity and part count increase
Solution Approach 1:
The connector barrel integrates multiple functions into a single component: it provides structural support for electrical circuitry, guides connector positioning, and seals the interface between internal and external connectors. This merging of support, guidance, and sealing functions into one integrated barrel structure reduces the number of separate components needed while maintaining reliable electrical circuitry support
2Reliability
If more separate components are used for securing connectors, then the securement is improved, but the manufacturing complexity and assembly steps increase
Solution Approach 1:
The connector barrel incorporates self-aligning features through its geometric design, including tapered surfaces and positioning ribs that automatically guide connectors into correct positions during assembly. The integrated sealing lips and retention features provide self-sealing and self-securing functions without requiring additional separate components or complex assembly procedures
Solution Approach 2:
The connector barrel serves multiple functions simultaneously: it acts as a structural support element, a guiding mechanism for connector alignment, a sealing barrier, and a retention feature. This multi-functionality eliminates the need for multiple separate components for support, guidance, sealing, and securement, simplifying both manufacturing and assembly
3Object-affected harmful factors
If traditional sealing methods are used at the housing opening, then sealing can be achieved, but the number of parts and manufacturing steps increase
Solution Approach 1:
The sealing function is merged into the connector barrel structure itself through integrated sealing lips and flexible sealing elements that are part of the barrel. This eliminates the need for separate sealing components such as gaskets or seals, achieving effective sealing while reducing the total number of parts
Data Source
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AI summary
A battery module includes a housing having a wall. The wall includes an opening extending from an inner surface of the wall facing an interior of the housing to an outer surface of the wall opposite to the inner surface. The battery module also includes a connector barrel having a first open end, a second open end, and a body portion extending between the first and second open ends. The body portion is positioned within the opening of the wall, the first open end is positioned within the interior of the housing, and the second open end is positioned external to the housing. A ridge on the body portion is disposed proximate to the outer surface of the wall, and a first circumferential bump on the body portion is disposed proximate to the inner surface of the wall. The battery module also includes a securement component disposed within a space defined by the first circumferential bump of the connector barrel. The wall is sandwiched between the ridge of the connector barrel and the securement component.