Resealable Guide Tubes for Sealed Battery Pack Voltage Testing

Solution Overview

Problem

Existing traction battery packs face challenges in measuring high voltage electrical properties without compromising the sealed integrity of the enclosure assembly, particularly when high voltage outputs are switched off, requiring invasive procedures or specialized tools.

Innovation Solution

Incorporating resealable guide tubes made of non-conductive materials like polytetrafluoroethylene (PTFE) that extend from inside the enclosure assembly to a high voltage measuring point, allowing a measurement probe to be guided directly to the point for electrical property measurement without opening the enclosure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the enclosure assembly is opened to access the battery array for measurement, then electrical property measurement is enabled, but the sealed integrity of the enclosure assembly is compromised

Engineering Contradiction:

Improvemeasurement accessibilityVSAvoidsealed integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The enclosure assembly is segmented by incorporating a guide tube that creates a separate access pathway through the wall. This allows the measurement probe to access the battery array through the guide tube opening rather than opening the enclosure, thus maintaining sealed integrity while enabling measurement accessibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The guide tube acts as an intermediary structure that bridges the external measurement environment and the internal battery array environment. It provides a controlled passage for the measurement probe to reach the battery array without compromising the enclosure's sealed integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If invasive procedures are used to measure electrical properties when high voltage outputs are switched off, then measurement is enabled, but the complexity of the measurement process increases

Engineering Contradiction:

Improvemeasurement efficiencyVSAvoidmeasurement procedure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The guide tube is pre-installed and positioned to provide direct access to the battery array during manufacturing or assembly. This preliminary action eliminates the need for complex invasive procedures during measurement, allowing operators to simply insert the probe through the guide tube opening for efficient measurement.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If the enclosure cover is removed for measurement access, then electrical property measurement is enabled, but the protection of internal components from environmental factors is reduced

Engineering Contradiction:

Improvemeasurement accessibilityVSAvoidenvironmental exposure

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The enclosure assembly is segmented by incorporating a guide tube that creates a separate access pathway through the wall. This allows the measurement probe to access the battery array through the guide tube opening rather than opening the enclosure, thus maintaining sealed integrity while enabling measurement accessibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The guide tube acts as an intermediary structure that bridges the external measurement environment and the internal battery array environment. It provides a controlled passage for the measurement probe to reach the battery array without compromising the enclosure's sealed integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250015376A1Resealable guide tubes for facilitating electrical property measurements within traction battery packs

Publication Date: 2025.01.09 FORD GLOBAL TECH LLC

AI summary

Resealable guide tubes are provided for use within traction battery packs. One or more resealable guide tubes may be arranged such that a first portion of each guide tube extends inside an enclosure assembly of the traction battery pack and a second portion of each guide tube extends outside of the enclosure assembly. Each guide tube may be sized and shaped for guiding a measurement probe of a testing device directly to a high voltage measuring point located inside the traction battery pack. The testing device may then be utilized to measure one or more electrical properties associated with the traction battery pack.