Multifunctional High-Voltage Connector Integrating Switch and Fuse
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Solution Overview
Problem
Existing battery product connectors, such as high-voltage connectors, Manual Service Disconnects, and fuses, are independent components that increase connection resistance, require multiple mounting holes, reduce sealing reliability, and occupy more space when used together, hindering integration and increasing complexity.
Innovation Solution
A multifunctional high-voltage connector that integrates switch and high-voltage connection functions into a single component, featuring a conductive connection structure with mating terminals and a harness assembly, reducing connection resistance and space occupancy by sharing a pedestal and eliminating the need for adapters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent connectors (high-voltage connector, MSD, fuse) are used separately, then each connector can perform its specific function reliably, but the connection resistance increases and the mounting space increases
Solution Approach 1:
The patent combines the high-voltage connector, MSD (Manual Service Disconnect), and fuse into a single integrated connector assembly. The housing contains all three functional components, with the high-voltage terminals electrically connected to both the MSD and fuse elements. This merging eliminates the need for separate connector installations and reduces overall system complexity while maintaining the reliability of each individual function.
Solution Approach 2:
The integrated connector serves multiple functions simultaneously: it provides high-voltage electrical connection, enables manual service disconnect capability, and incorporates fuse protection. The single connector assembly universalizes the solution by replacing multiple specialized components with one multi-functional unit, reducing mounting requirements and connection points.
2Adaptability or versatility
If multiple independent connectors are installed separately, then each connector can be optimized for its specific function, but the number of mounting holes increases and sealing interfaces increase
Solution Approach 1:
The patent merges multiple connectors into a single housing unit that requires only one mounting location. The housing is designed as a single assembly with integrated MSD and fuse components, eliminating the need for multiple separate mounting holes. This reduction in mounting interfaces directly improves sealing reliability by minimizing the number of potential leak paths.
3Adaptability or versatility
If multiple independent connectors are used, then comprehensive protection and control functions are achieved, but the mounting space occupied increases
Solution Approach 1:
The patent combines the high-voltage connector, MSD, and fuse into a single compact housing assembly. The housing contains all functional components in an integrated arrangement, significantly reducing the mounting space required compared to installing three separate connectors. The compact design maintains comprehensive protection and control functions while occupying minimal battery pack space.
Data Source
AI summary
The present disclosure provides a multifunctional high-voltage connector and a battery product, the multifunctional high-voltage connector comprises: an upper cover; a pedestal; a conductive connection structure; two mating terminals; and a harness assembly. The conductive connection structure is used to make the two mating terminals be connected in series, and the harness assembly is directly connected to one of the mating terminals. When the upper cover and the pedestal are assembled, the conductive connection structure is simultaneously in contact with the two mating terminals, thereby turning on the high-voltage circuit. When the battery product requires maintenance, the upper cover is directly detached from the base, thereby turning off the high-voltage circuit. The battery product can be electrically connected to an external device via the harness assembly. The multifunctional high-voltage connector integrates both a switch function and a high-voltage connection function, therefore the connection resistance is greatly reduced.