Flexible Battery Connector Assembly for Vibration and Fire Risk
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Solution Overview
Problem
Battery connector systems in harsh environments, such as those used in electric-vertical-take-off-and-landing (eVTOL) systems, are prone to damage from vibration and shock, and there is a risk of fire due to overheating, necessitating a robust and reliable connection solution.
Innovation Solution
A battery connector assembly featuring flexible jumper conductors that connect battery connectors securely, accommodating relative movement and stress, while also incorporating fire-resistant materials and sealed housings to prevent overheating and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar is used to electrically connect battery terminals, then a fixed connection is established, but the connection is susceptible to damage from vibration and shock
Solution Approach 1:
The patent replaces the static, rigid busbar connection with a dynamic cable assembly that includes flexible conductors and movement-accommodating features. The cable can flex and move with the battery, transforming the connection from rigid to adaptable, thereby resisting vibration and shock damage while maintaining electrical connectivity.
Solution Approach 2:
The patent employs flexible cable assemblies with movable connections instead of rigid busbars. The flexible conductor and its protective sheath allow the connection to bend and move, accommodating thermal expansion, contraction, and mechanical stress from vibration, thus preventing connection failure in harsh environments.
2Power
If battery connectors are designed for high power and usage, then power delivery is enhanced, but the risk of fire due to overheating increases
Solution Approach 1:
The patent utilizes composite cable assemblies combining conductive materials with fire-resistant insulation and protective layers. The multi-material construction includes heat-dissipating elements and fire-retardant coatings that enable high power transmission while preventing overheating and fire, thus resolving the contradiction between power delivery and thermal safety.
Solution Approach 2:
The cable assembly acts as an intermediary between the battery terminals, incorporating heat-dissipating features and fire-resistant materials that mediate the thermal effects of high power transmission. This intermediary structure allows high current flow while preventing direct heat transfer that could cause overheating or fire.
3Reliability
If a robust battery connector system is implemented, then resistance to vibration and shock is improved, but the device complexity increases
Solution Approach 1:
The patent divides the battery connection system into modular cable assemblies, each with specific functions (electrical connection, mechanical flexibility, thermal management, fire resistance). This segmentation allows each component to be optimized independently for its specific function, achieving robust vibration and shock resistance without unnecessarily increasing overall system complexity.
Data Source
AI summary
A battery connector assembly includes a first battery connector having a first battery contact. The first battery contact has a first separable mating interface. The first battery contact is electrically connected to a first battery terminal of a first battery module. The battery connector assembly includes a second battery connector having a second battery contact. The second battery contact has a second separable mating interface. The second battery contact is electrically connected to a second battery terminal of a second battery module. The battery connector assembly includes a jumper electrically connects the first battery connector and the second battery connector. The jumper includes a jumper conductor has a first end and a second end. The first end of the jumper conductor is electrically connected to the first battery contact. The second end of the jumper conductor is electrically connected to the second battery contact.