High-Voltage Cable Connector With Multi-Direction Cable Alignment
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Solution Overview
Problem
Existing electrical connectors for high voltage battery packs are limited in their ability to accommodate multiple cable alignments, which can complicate installation and reduce flexibility in high voltage applications.
Innovation Solution
An electrical connector system comprising a box frame with a terminal receiving cavity and a cable receiving housing that allows for multiple cable alignment configurations, including vertical and horizontal orientations, using a multipart assembly with interchangeable components to adapt to different cable directions and ensure secure, durable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed alignment electrical connector is used, then the connection structure is simple, but it cannot accommodate multiple cable alignments
Solution Approach 1:
The connector is divided into a box frame component and a cable receiving housing component that can be selectively assembled. The box frame provides a fixed terminal receiving cavity, while the cable receiving housing can be attached to different frame faces to accommodate various cable alignments, resolving the contradiction between structural simplicity and alignment versatility.
Solution Approach 2:
The box frame is designed with multiple frame faces that can each receive the cable receiving housing, enabling the same base structure to accommodate cables from different directions (vertical, horizontal, angled). This multi-functional design allows a single connector to serve multiple cable alignment configurations without requiring completely different connector designs.
2Adaptability or versatility
If a multipart assembly with interchangeable components is used, then multiple cable alignments are accommodated, but the assembly complexity increases
Solution Approach 1:
The box frame is pre-configured with multiple frame faces that are all capable of receiving the cable receiving housing. This preliminary preparation allows for quick assembly by simply attaching the housing to the appropriate face, reducing the complexity of the assembly process despite the multipart design.
Solution Approach 2:
The cable receiving housing is designed to attach to the box frame in a nested configuration, where the housing integrates with the frame structure. This nesting approach minimizes the overall assembly complexity by having components fit together rather than requiring separate mounting operations for each part.
Data Source
AI summary
An electrical connector for the high voltage electrical connection of electrical cables to a battery pack can be selectively configured to align the electrical cables in multiple directions. The electrical connector includes a box frame mountable to the battery pack and having one or more frame faces with an access opening therein that accesses a terminal receiving cavity of the box frame. A cable receiving housing is attachable to the frame face and configured to align and direct the electrical cables to the terminal receiving cavity. A cover plate may be used to cover the access opening in the others frame faces.