External Electric Header Assembly for Ergonomic Battery Pack Sealing
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Solution Overview
Problem
Current electric header designs for connecting traction battery packs to external loads in vehicles are ergonomically challenging, leading to unacceptable operator postures during assembly and potential leakage of potting material, which compromises the integrity of the pack.
Innovation Solution
Optimized electric header assemblies with a bipartite or tripartite design featuring an interconnect terminal, a compressible header seal, and a main header, formed from insulating polymers, which are mounted externally to the pack frame, ensuring leak-proof connections and reducing part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electric headers are mounted internally within the battery pack assembly, then connection integrity is maintained, but assembly ergonomics deteriorate and operator postures become unacceptable
Solution Approach 1:
The patent inverts the conventional mounting approach by mounting electric headers from the exterior of the battery pack rather than from the interior. This allows assembly workers to access and secure headers while standing in ergonomic positions, eliminating the need to reach into confined internal spaces and adopt unacceptable postures.
2Reliability
If traditional header designs are used, then electrical connection is achieved, but potting material leakage occurs compromising pack integrity
Solution Approach 1:
The patent introduces a sealing layer as an intermediary component between the electric header and the battery pack housing. This sealing layer acts as a barrier that prevents potting material from leaking along the interface between the header and housing, thereby maintaining pack integrity while allowing the header to perform its electrical connection function.
3Productivity
If multiple separate components are used for electric header assembly, then functional requirements are met, but system complexity and assembly time increase
Solution Approach 1:
The patent merges the electric header, mounting features, and sealing layer into an integrated assembly unit. This consolidation reduces the number of discrete parts that need to be handled and assembled separately, thereby reducing assembly time and operational complexity while maintaining all necessary electrical and sealing functions.
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 design enhances ergonomic assembly, reduces system complexity, minimizes assembly time and cost, and prevents potting material leakage, thus protecting internal components from mechanical and temperature shock.
Implementation Method 1
a compressible header seal... mounted externally to the pack frame, ensuring leak-proof connections
Data Source
AI summary
Presented are optimized electric header designs for ergonomic battery unit assembly and potting leakage prevention, methods for making/using such electric headers, and vehicles powered by battery packs equipped with such electric headers. An electric header assembly includes an interconnect terminal that is formed with an insulating polymer and couples to a set of terminal connectors that is electrically connected to a cluster of battery cells inside a protective housing of a battery unit. A header seal, which is formed with a compressible polymer, mounts onto the interconnect terminal and compresses against the protective housing. A main header, which is formed with an insulating polymer, couples to or is integrally formed with the interconnect terminal. The main header couples to a connector plug to thereby electrically connect the terminal connectors in the interconnect terminal to an external load. The main header mounts to an external surface of the unit housing.