High-Voltage Connector Fuse Segmentation
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Solution Overview
Problem
Traditional manual service disconnect (MSD) connectors for battery products become larger and heavier as current requirements increase, complicating assembly and maintenance due to the integrated fuse, which affects the size and weight of the plug, making the assembly process more difficult and time-consuming.
Innovation Solution
A multifunctional high-voltage connector design where the fuse, socket, and plug are separate entities, allowing the plug to be smaller and lighter, facilitating easier assembly and maintenance by enabling independent size and weight optimization, with the fuse and socket terminals positioned to allow for simple on/off connections and circuit protection without increasing the plug's size or weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse size is increased to protect the battery from higher current, then the battery protection capability is improved, but the plug size and weight increase, making assembly more difficult
Solution Approach 1:
The connector is divided into separate functional modules: the fuse is integrated into the socket housing while the plug remains separate and compact. This segmentation allows the fuse to be sized for optimal protection without increasing plug dimensions, resolving the contradiction between protection capability and assembly ease.
Solution Approach 2:
The fuse function is extracted from the plug and relocated to the socket housing. This extraction allows the plug to maintain a small, lightweight design while the socket housing accommodates the larger fuse, eliminating the direct relationship between fuse size and plug dimensions.
2Reliability
If the fuse size is increased to protect the battery from higher current, then the battery protection capability is improved, but the plug weight increases, affecting assembly efficiency
Solution Approach 1:
The connector system is segmented into fuse-containing socket housing and separate plug. This segmentation isolates the weight of the larger fuse to the stationary socket housing, keeping the movable plug lightweight for easy handling and assembly.
Solution Approach 2:
The fuse is extracted from the plug and placed in the socket housing. This extraction removes the fuse weight from the plug, allowing the plug to remain lightweight while the socket housing provides the necessary protection capability.
3Reliability
If the plug size is increased to accommodate a larger fuse, then the battery protection capability is improved, but the assembly time between socket and plug increases
Solution Approach 1:
The connector is segmented so that the fuse is housed in the socket while the plug remains compact. This segmentation allows the plug to be quickly assembled into the socket without the time-consuming handling of a large integrated plug, reducing assembly time while maintaining protection capability.
Solution Approach 2:
The fuse is extracted from the plug and placed in the socket housing. This extraction allows the plug to maintain a compact size for rapid assembly, while the socket housing contains the larger fuse, eliminating the trade-off between protection capability and assembly speed.
Data Source
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AI summary
The present invention provides a multifunctional high-voltage connector and a battery product. The multifunctional high-voltage connector includes: a fuse, a socket, and a plug. The socket includes a base and a socket terminal. The plug includes a seat and a plug terminal. The base includes: a first main body portion; a first accommodating portion, protruding from the first main body portion; and a second accommodating portion, protruding from the first main body portion and provided to be spaced apart from the first accommodating portion. The fuse is accommodated in the first accommodating portion. At least a part of the socket terminal is accommodated in the second accommodating portion. The seat of the plug is inserted into the second accommodating portion of the base. Because an on/off connection part and a circuit protection part of the multifunctional high-voltage connector are separately provided, size and weight of the plug are independent of the fuse; when the multifunctional high-voltage connector needs to be closed or opened, it is only necessary to insert the plug into the socket or disconnect the plug from the socket. Based on a positional relationship among the fuse, the plug and the socket, the plug is small in size and light in weight, thereby facilitating assembly between the plug and the socket.