Pack Connector Noise Filtering for High-Density Battery Packs
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Solution Overview
Problem
Existing battery packs face issues with noise interference from external sources, such as inverters, which can cause malfunctions in internal components and connected electronic devices, and conventional noise filtering solutions complicate the battery pack structure and reduce energy density.
Innovation Solution
A battery pack design incorporating a pack connector with an embedded filtering member, such as a circuit board, to filter noise at the connection port, utilizing a ground terminal and housing member for efficient noise dissipation without increasing volume or complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a filter element such as a ferrite core filter is wound on a cable connected to a connector, then noise filtering is improved, but the volume of the battery pack increases and energy density is lowered
Solution Approach 1:
The filtering function is extracted from the cable assembly and integrated into the connector housing itself. The housing member incorporates filtering structures directly within the connector body, eliminating the need for separate ferrite core filters wrapped around cables, thereby reducing overall volume while maintaining noise filtering effectiveness.
Solution Approach 2:
The connector and filtering functions are merged into a single integrated component. The housing member serves both as the structural connector body and as the noise filtering element, combining what were previously separate components (connector + external filter) into one unified structure that reduces total volume.
2Object-affected harmful factors
If a filter element such as a ferrite core filter is wound on a cable connected to a connector, then noise filtering is improved, but the structure of the battery pack becomes complicated
Solution Approach 1:
The filtering function is extracted from external cable assemblies and embedded directly into the connector housing. This integration eliminates the need for separate filtering components and their associated mounting structures, simplifying the overall battery pack architecture while maintaining effective noise filtering.
Solution Approach 2:
The housing member is designed to perform multiple functions simultaneously: it provides structural support for the connector, houses the filtering elements, and serves as the mounting interface for the cable assembly. This multi-functionality reduces the number of separate components needed, thereby simplifying the overall structure.
3Object-affected harmful factors
If the inner space of the battery pack is narrowed to accommodate filter elements, then noise filtering is improved, but the space for other components such as secondary batteries is reduced
Solution Approach 1:
The connector housing and filtering elements are merged into a single integrated component that occupies the same space as the connector assembly would occupy anyway. This means the filtering function is added without requiring additional volume beyond what is already allocated for the connector, preserving space for secondary batteries and other components.
Solution Approach 2:
The filtering elements are nested within the existing connector housing structure. Rather than adding external filtering components that would increase overall volume, the filters are placed inside the hollow space of the connector body, utilizing otherwise wasted space and maintaining the original external dimensions.
4Object-affected harmful factors
If a structure for fixing the filter element is provided, then noise filtering is improved, but the manufacturing process becomes complicated and internal design is difficult
Solution Approach 1:
The fixing structure and filtering elements are merged into the housing mold as integrated features. Rather than requiring separate assembly steps to attach filters to the connector, the filters are built into the housing structure during molding, eliminating additional manufacturing steps and simplifying the production process.
Solution Approach 2:
The filtering elements and their mounting structures are pre-formed as integral parts of the housing during the molding process. This preliminary formation eliminates the need for subsequent assembly operations to install and secure the filters, thereby simplifying manufacturing and reducing assembly 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
Effectively blocks noise ingress and egress, maintains energy density, simplifies manufacturing, and reduces internal component complexity by shortening noise paths and minimizing the number of PCB layers.
Implementation Method 1
a filtering member embedded in the connection port and configured to filter noise on an electric path between the connection port and the control cable
Data Source
AI summary
A battery pack, which includes a pack connector having a simple structure and effectively preventing the inflow and outflow of noise. The battery pack includes a cell assembly having at least one secondary battery; a battery control unit configured to control a charging and discharging operation of the cell assembly; a pack case configured to accommodate the cell assembly and the battery control unit in an inner space thereof; and a pack connector connected to the battery control unit through a control cable and including a connection port provided to at least one side of the pack case to be exposed out for the connection with a connecting terminal of an external device and a filtering member embedded therein to filter noise on an electric path between the connection port and the control cable.