Floating High-Voltage Connector Assembly for EV Battery Vibration
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Solution Overview
Problem
Existing electric vehicle battery connection methods using sedentary electrodes are prone to damage from vertical 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 a separable planar electrical connection, allowing for floating displacement to mitigate extrusion forces, and a detachable seal connection between mounting seats for improved waterproofing, 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 sedentary electrodes is used, then electrical connection is achieved, but the electrodes are easily damaged when acted by vertical forces
Solution Approach 1:
The patent transforms the traditional fixed sedentary electrode into a dynamic spring electrode that can elastically deform under vertical forces. The spring electrode is configured to be pressed against the battery side electrical connector, allowing it to absorb extrusion forces through elastic deformation rather than transmitting them directly to rigid contact points, thereby preventing damage while maintaining reliable electrical connection.
2Stability of the object's composition
If rigid electrical connection structure is used, then connection stability is achieved, but damage occurs under extrusion forces
Solution Approach 1:
The patent incorporates a spring electrode that acts as a pre-configured cushioning element. The spring is designed with appropriate stiffness and preload to absorb extrusion forces before they can damage the electrical connection components. This beforehand cushioning mechanism protects the rigid mounting structure from damage while maintaining stable electrical connection.
3Object-affected harmful factors
If detachable seal connection between mounting seats is used, then waterproof performance is improved, but device complexity increases
Solution Approach 1:
The patent combines the sealing function with the electrical connection function by integrating the seal structure into the mounting seat assembly. The detachable seal connection is implemented as part of the overall connector design, where the seal ring or sealing surface is incorporated into the mounting seat structure itself, rather than being a separate component. This merging approach improves waterproof performance while minimizing the increase in device complexity.
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 high-voltage assemblies, ensures stable electrical connections, and enhances the waterproof performance of the electrical connection device, maintaining reliability 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, which 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
A vehicle side electrical connector. The vehicle side electrical connector comprises a first mounting seat, a first high-voltage assembly and a first low-voltage assembly; wherein the first high-voltage assembly comprises of a first high-voltage pole, wherein the first high-voltage pole includes an electrical contact end and a wiring end, wherein the first high-voltage assembly comprises a flexible electrical connector and a high-voltage plug, one end of the flexible electrical connector is in a floating electrical connection with the wiring end of the first high-voltage pole, and the other end of the flexible electrical connector is in a floating electrical connection with the high-voltage plug; the flexible electrical connector adapts the relative displacement change in axial, radial and all directions between the first high-voltage pole and the high-voltage plug through a flexible cavity. By means of the vehicle side electrical connector, the first high-voltage assembly can be prevented from hard damage.