Modular Electrical Connector for Replaceable Sensor Contacts
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Solution Overview
Problem
Traditional electrical connectors in BMS battery management systems of new energy vehicles require disassembly of the entire battery pack for temperature sensor replacement, which is difficult and may cause damage, and also necessitate recalibration and replacement of mating elements for different components.
Innovation Solution
An electrical connector design featuring an insulative housing with receiving slots for first and second contacts, and a connecting element, where the second contacts are pluggably connected with the first contacts and the connecting element, allowing for reliable fixation and easy replacement of second contacts for different use requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature sensor is fixed on the PCB or FPC by welding, then the connection is reliable, but the replacement requires disassembly of the entire battery pack which is difficult and may cause damage
Solution Approach 1:
The electrical connector is divided into separate components: a first contact fixed on the PCB/FPC, a second contact that can be replaced, and a connecting element. This segmentation allows the second contact to be replaced independently without disassembling the entire battery pack, while the first contact remains fixed to maintain reliable connection.
Solution Approach 2:
The connector design introduces dynamic replaceability through the pluggable second contact and connecting element, allowing the system to transition from a fixed welded connection to a modular connection that can be easily assembled and disassembled for replacement while maintaining reliable electrical connection.
2Ease of repair
If the entire battery pack is disassembled for temperature sensor replacement, then the sensor can be replaced, but the operation is difficult and may cause damage to components
Solution Approach 1:
The connector is segmented into replaceable second contact and connecting element components that can be accessed and replaced at the connector location without disassembling the battery pack, significantly reducing replacement complexity.
Solution Approach 2:
The second contact is extracted as a separate replaceable component from the fixed first contact on the PCB, allowing it to be removed and replaced independently at the connector without affecting the battery pack assembly or other components.
3Adaptability or versatility
If different mating elements are replaced for different use requirements, then the connector can match different components, but the replacement process is complex
Solution Approach 1:
The first contact on the PCB serves as a universal interface that can mate with different second contacts and connecting elements for various components (temperature sensors, humidity sensors, etc.), providing multi-functionality and adaptability without requiring replacement of the fixed PCB-mounted contact.
Solution Approach 2:
Instead of replacing the fixed mating element on the PCB for different components, the design inverts the approach by making the connector-side second contact and connecting element replaceable, while the PCB-side first contact remains fixed and universal.
Data Source
AI summary
An electrical connector includes an insulative housing, at least a first contact and a connecting element. The insulative housing defines at least a receiving slot extending along a front-and-back direction. The first contact is received in the corresponding receiving slot, the connecting element is partially received in the receiving slot. The electrical connector further comprises at least a second contact pluggably connected with the first contact and the connecting element, and the second contact is completely received in the receiving slot.