Sliding Battery Pack Module Connector Without Jumper Wires
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Solution Overview
Problem
Existing electrified vehicle battery packs face challenges in efficiently connecting battery pack modules to sense lead headers without the need for jumper wires, which can complicate assembly and increase weight and damage risk.
Innovation Solution
A traction battery assembly with a battery pack module that slides relative to an array sense lead header from a disengaged to an engaged position, using mechanical fasteners and a module connector, eliminating the need for jumper wires and reducing wiring complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If jumper wires are used to connect battery pack modules to sense lead headers, then electrical connectivity is achieved, but assembly complexity increases and damage risk increases
Solution Approach 1:
The patent merges the electrical connection function and mechanical support function into a single integrated module connector. The module connector directly engages with the sense lead header to provide both structural support and electrical connectivity, eliminating the need for separate jumper wires and reducing overall system complexity.
Solution Approach 2:
The patent extracts the jumper wire component from the system by implementing direct engagement between the module connector and sense lead header. This removal of the intermediate jumper wire component simplifies the wiring system and reduces potential failure points while maintaining reliable electrical connectivity.
2Reliability
If jumper wires are used for connection, then electrical connectivity is established, but weight increases
Solution Approach 1:
The patent removes the jumper wire components from the battery pack system by implementing direct engagement between the module connector and sense lead header. This extraction of unnecessary components reduces the overall weight of the battery pack while maintaining reliable electrical connectivity for sensing and control functions.
3Reliability
If traditional wiring methods are used, then electrical connections are established, but assembly damage risk increases
Solution Approach 1:
The patent combines the electrical connection function and mechanical support function into a single integrated module connector that directly engages with the sense lead header. This integration eliminates the need for separate jumper wires and reduces the number of assembly steps, thereby lowering the risk of assembly damage while ensuring stable electrical connections.
Solution Approach 2:
The module connector is pre-configured with integrated electrical contacts and mechanical engagement features that align with the sense lead header. This preliminary configuration ensures proper alignment and connection during assembly, reducing the risk of misalignment or damage that could occur with traditional wiring methods.
Data Source
AI summary
A traction battery assembly includes, among other things, an array sense lead header of a battery array, a plurality of sense leads extending from the array sense lead header to areas of the battery array, and a battery pack module having a module connector. The battery pack module is configured to move relative to the battery array from a disengaged position where the module connector the array sense lead header are disengaged to an engaged position where the module connector and the array sense lead header are engaged.