Floating High-Voltage Battery Connector for Extrusion Stability
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Solution Overview
Problem
Existing electric vehicle battery connectors with stationary electrodes are prone to damage due to vertical extrusion forces, leading to instability and reliability issues in electrical connections.
Innovation Solution
The design incorporates a vehicle side electrical connector with a first high-voltage assembly and a second high-voltage assembly in separable planar electrical connection, allowing for floating displacement to mitigate extrusion forces, and a detachable seal connection between mounting seats for improved waterproof performance, along with conductive elastic components and flexible electrical connectors for enhanced stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional vehicle side electrical connector with fixed pole is used, then electrical connection can be established, but the pole is easily damaged when suffering vertical extrusion force
Solution Approach 1:
The patent transforms the fixed rigid pole structure into a dynamic spring-loaded structure. The spring component allows the conductive pole to dynamically adjust its position and absorb vertical extrusion forces through elastic deformation, preventing damage while maintaining reliable electrical connection. The spring enables the connector to adapt to vibrations and misalignments during vehicle operation.
Solution Approach 2:
The spring component acts as a pre-configured cushioning element that anticipates and absorbs vertical extrusion forces before they can damage the pole. The spring is designed to compress under expected load conditions, providing advance protection against impact forces during battery installation, vehicle vibration, or thermal expansion/contraction cycles.
2Device complexity
If stationary electrodes are used in vehicle side electrical connector, then connection structure is simple, but the connector is prone to damage under vertical extrusion force
Solution Approach 1:
The invention introduces a spring mechanism that adds dynamic capability to the connector structure. This dynamic element allows the system to accommodate vertical movements and vibrations while maintaining stable electrical contact, significantly improving reliability without substantially complicating the overall connector design.
Solution Approach 2:
The spring component changes the mechanical parameters of the connector by introducing elasticity and compliance. The spring constant and compression range are designed to match the expected operational conditions, allowing the connector to absorb energy from vertical extrusion forces while maintaining reliable electrical connection throughout the operational lifecycle.
3Stability of the object's composition
If rigid electrical connection is used, then connection stability is good, but damage resistance under extrusion force is poor
Solution Approach 1:
The spring-loaded design creates a dynamic electrical connection that maintains stable contact through elastic force. The spring continuously applies contact force to ensure reliable electrical connection while simultaneously absorbing impact forces that would otherwise damage rigid connections. This dynamic system adapts to varying operational conditions while maintaining both stability and damage resistance.
Solution Approach 2:
The spring component provides advance cushioning by being pre-compressed or designed to compress under expected load conditions. This beforehand cushioning absorbs vertical extrusion forces before they can compromise the electrical connection or damage the pole structure, maintaining both contact stability and damage resistance throughout the connector's operational life.
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
This solution prevents hard damage to the connectors, ensures stable electrical contact, and enhances the reliability and waterproof performance of the electrical connections, maintaining stability even under vibrating conditions.
Implementation Method 1
the first high-voltage assembly and the second high-voltage assembly are in a separable planar electrical connection, wherein the first high-voltage assembly and the second high-voltage assembly can possess a certain floating displacement due to the extrusion along the axis therebetween, in order to eliminate the generated extrusion force
Data Source
AI summary
An electrical connection device. The electrical connection device comprises a vehicle side electrical connector comprising a first mounting seat, a first high-voltage assembly and a first low-voltage assembly; and a battery side electrical connector comprising a second mounting seat, a second high-voltage assembly and a second low-voltage assembly. The first high-voltage assembly comprises a first high-voltage pole, a flexible electrical connector and a high-voltage plug, wherein the first high-voltage pole includes an electrical contact end and a wiring end; wherein one end of the flexible electrical connector is in a floating electrical connection with the wiring end of the first high-voltage pole, the high-voltage plug is in a floating electrical connection with the other end of the flexible electrical connector. By means of the electrical connection device, the first high-voltage assembly and the second high-voltage assembly can be prevented from hard damage, the stability of the electrical contact between the first high-voltage assembly and the second high-voltage assembly can be ensured.