Description:TECHNICAL FIELD
[0001] The present disclosure relates to automotive technology. In particular, the present disclosure relates to a connector pair assembly, incorporating floatable slots that are self-adjusted while connecting with conductive pins, thereby enabling seamless connections between vehicular components.

BACKGROUND
[0002] In conventional vehicles, a common issue with typical Ingress Protection (IP)-rated connectors is a possibility of water getting into sealed areas through terminals. A general concern observed in various batteries is an absence of vents to balance internal and external pressure. In situations of low pressure within a battery, water near the signal harness may follow this wire and enter the battery due to the pressure differences.
[0003] Commonly used integrated connectors seamlessly combine power and signal elements, featuring IP ratings and encapsulation on one end. This encapsulation serves a dual purpose maintaining the IP ratings and efficiently managing terminal heating. Typically, such integrated connectors are used in charging applications and these integrated connectors often incorporate a potting material on only one side of the connectors, leaving the other side of the connectors without potting. However, challenges arise in instances of water leaks due to pressure differences and potential potting issues, especially when the potting material is necessary on both ends. This situation may lead to signal terminals becoming rigid and, consequently, affecting alignment. In the development of the connectors with the IP ratings through wires, addressing all ingress failure modes is crucial for ensuring robust performance. In battery packs lacking pressure equalization vents, the potential exists for water to be drawn inside, especially around thin signal wires. The challenge with encapsulation is a possible leakage of the potting material into a mating side, leading to complications in crimp sealing.
[0004] . However, the use of encapsulation in such scenarios has the drawback of making signal terminals rigid, contrasting with typical flexibility in signal connectors without potting. Consequently, the connectors of this nature often features potting on one side, while leaving the other end without encapsulation.
[0005] In the context of a battery-integrated connector, applying the potting on both ends is necessary to establish an IP-rated interface on both sides, thereby minimizing a risk of battery terminal shorting. In the battery-integrated connector, the signal terminals may consist of bent sheet metal components, and potting imparts rigidity to both ends of these sheet metal signal terminals. This increased rigidity potentially leads to alignment issues, requiring a corresponding solution.
[0006] Therefore, there is, a need to address the above-mentioned drawbacks, along with any other shortcomings, or at the very least, to provide a viable alternative connector pair assembly.

OBJECTS OF THE PRESENT DISCLOSURE
[0007] A general object of the present disclosure is to provide an efficient and a reliable connector pair assembly that obviates the above-mentioned limitations of existing assemblies.
[0008] An object of the present disclosure is to provide a connector pair assembly that incorporates floatable slots self-adjusted to connect with conductive elements, thereby providing enhanced adaptability and ease of connection between vehicular components.

SUMMARY
[0009] Aspects of the disclosure relate to automotive technology. In particular, the present disclosure provides a connector pair assembly, incorporating floatable slots that is self-adjusted while connecting with conductive pins, thereby enabling seamless connections.
[0010] In an aspect, the present disclosure relates to a connector pair assembly for vehicular components. The connector pair assembly includes a first connector and a second connector. The first connector includes one or more conductive elements having a first end and a second end, where the first end is potted using a potting material. The second connector includes a first section and a second section, where the first section is potted using the potting material and the second section is configured with one or more floatable slots. Each of the one or more floatable slots is self-adjusted to connect with the second end of each of the one or more conductive elements of the first connector.
[0011] In an embodiment, the first end of each of the one or more conductive elements may include a Printed Circuit Board (PCB) header and a solder node. The PCB header may include a gasket member. The solder node on a distal part of the first end may be connected with an electronic element integrated within a vehicular component.
[0012] In an embodiment, the PCB header and the solder node may be potted using the potting material.
[0013] In an embodiment, the gasket member may be attached to an outer housing of the second section, when each of the one or more floatable slots is connected to the second end of each of the one or more conductive elements of the first connector.
[0014] In an embodiment, the second connector may be configured with one or more cables, wherein each of the one or more cables facilitate an electrical connection corresponding to each of the one or more floatable slots.
[0015] In an embodiment, a first portion of the one or more cables may be surrounded with a sealing element, and a second portion of each of the one or more cables may facilitate the electrical connection between each of the one or more conductive elements and each of the one or more floatable slots.
[0016] In an embodiment, the first portion of the one or more cables may be connected to another vehicular component, and the first portion of each of the one or more cables and the sealing element may be potted using the potting material.
[0017] In an embodiment, the first portion of the one or more cables may be disposed in the first section of the second connector. The second portion of each of the one or more cables may be disposed corresponding to a rear end of each of the one or more floatable slots in the second section.
[0018] In an embodiment, the one or more floatable slots may be configured with a wire gasket, an insulation crimp barrel, and a wire crimp barrel.
[0019] In an embodiment, each of the one or more floatable slots may be configured with a predefined diameter to receive the second end of each of the one or more conductive elements of the first connector.
[0020] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0022] FIG. 1 illustrates a schematic view of an Electric Vehicle (EV), in accordance with embodiments of the present disclosure.
[0023] FIGs. 2A-2C illustrate schematic views of a connector pair assembly for vehicular components, in accordance with embodiments of the present disclosure.
[0024] FIG. 2D illustrates a schematic view of conductive elements, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION
[0025] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosures as defined by the appended claims.
[0026] For the purpose of understanding of the principles of the present disclosure, reference will now be made to the various embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present disclosure is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the present disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present disclosure relates.
[0027] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the present disclosure and are not intended to be restrictive thereof.
[0028] Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more” or “one or more elements is required.”
[0029] Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.
[0030] Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment,” “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
[0031] Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.
[0032] The terms “comprise,” “comprising,” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by “comprises... a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.
[0033] Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
[0034] For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in FIG. 1. Similarly, reference numerals starting with digit “2” are shown at least in FIG. 2.
[0035] An Electric Vehicle (EV) or a battery powered vehicle including, and not limited to two-wheelers such as scooters, mopeds, motorbikes/motorcycles; three-wheelers such as auto-rickshaws, four-wheelers such as cars and other Light Commercial Vehicles (LCVs) and Heavy Commercial Vehicles (HCVs) primarily work on the principle of driving an electric motor using the power from the batteries provided in the EV. Furthermore, the electric vehicle may have at least one wheel which is electrically powered to traverse such a vehicle. The term ‘wheel’ may be referred to any ground-engaging member which allows traversal of the electric vehicle over a path. The types of EVs include Battery Electric Vehicle (BEV), Hybrid Electric Vehicle (HEV), and Range Extended Electric Vehicle. However, the subsequent paragraphs pertain to the different elements of a Battery Electric Vehicle (BEV).
[0036] FIG. 1 illustrates a schematic view of an Electric Vehicle (EV), in accordance with embodiments of the present disclosure.
[0037] In construction, an EV (10) typically comprises a battery or a battery pack (12) enclosed within a battery casing and includes a Battery Management System (BMS), an on-board charger (14), a Motor Controller Unit (MCU), an electric motor (16), and an electric transmission system (18). The primary function of the above-mentioned elements is detailed in the subsequent paragraphs. The battery of the EV (10) (also known as Electric Vehicle Battery (EVB) or traction battery) is re-chargeable in nature and is the primary source of energy required for the operation of the EV (10), wherein the battery (12) is typically charged using the electric current taken from the grid through a charging infrastructure (20). The battery (12) may be charged using Alternating Current (AC) or Direct Current (DC), wherein in case of AC input, the on-board charger (14) converts the AC signal to DC signal after which the DC signal is transmitted to the battery (12) via the BMS. However, in case of DC charging, the on-board charger (14) is bypassed, and the current is transmitted directly to the battery (12) via the BMS.
[0038] The battery (12) is made up of a plurality of cells which are grouped into a plurality of modules in a manner in which the temperature difference between the cells does not exceed 5 degrees Celsius. The terms “battery”, “cell”, and “battery cell” may be used interchangeably and may refer to any of a variety of different rechargeable cell compositions and configurations including, but not limited to, lithium-ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium-ion polymer, nickel metal hydride, nickel cadmium, nickel hydrogen, nickel-zinc, silver zinc, or other battery type/configuration. The term “battery pack” as used herein may be referred to multiple individual batteries enclosed within a single structure or multi-piece structure. The individual batteries may be electrically interconnected to achieve a desired voltage and capacity for a desired application. The Battery Management System (BMS) is an electronic system whose primary function is to ensure that the battery (12) is operating safely and efficiently. The BMS continuously monitors different parameters of the battery (12) such as temperature, voltage, current, and so on, and communicates these parameters to the Electronic Control Unit (ECU) and the Motor Controller Unit (MCU) in the EV (10) using a plurality of protocols including and not limited to a Controller Area Network (CAN) bus protocol which facilitates the communication between the ECU/MCU and other peripheral elements of the EV (10) without the requirement of a host computer.
[0039] The MCU primarily controls/regulates the operation of the electric motor (16) based on the signal transmitted from the vehicle battery (12), wherein the primary functions of the MCU include starting of the electric motor (16), stopping the electric motor (16), controlling the speed of the electric motor (16), enabling the vehicle (10) to move in the reverse direction and protect the electric motor (16) from premature wear and tear. The primary function of the electric motor (16) is to convert electrical energy into mechanical energy, wherein the converted mechanical energy is subsequently transferred to the transmission system of the EV (10) to facilitate movement of the EV (10). Additionally, the electric motor (16) also acts as a generator during regenerative braking (i.e., kinetic energy generated during vehicle braking/deceleration is converted into potential energy and stored in the battery of the EV). The types of motors generally employed in EVs (10) include, but are not limited to a DC series motor, a Brushless DC motor (also known as BLDC motors), a Permanent Magnet Synchronous Motor (PMSM), Three Phase AC Induction Motors, and Switched Reluctance Motors (SRM).
[0040] The transmission system (18) of the EV (10) facilitates the transfer of the generated mechanical energy by the electric motor (16) to the wheels (22a, 22b) of the EV (10). Generally, the transmission systems (18) used in EVs (10) include single speed transmission system and multi-speed (i.e., two-speed) transmission system, wherein the single speed transmission system comprises a single gear pair whereby the EV (10) is maintained at a constant speed. However, the multi-speed/two-speed transmission system comprises a compound planetary gear system with a double pinion planetary gear set and a single pinion planetary gear set thereby resulting in two different gear ratios which facilitates higher torque and vehicle speed.
[0041] In one embodiment, all data pertaining to the EV (10) and/or charging infrastructure (20) are collected and processed using a remote server (known as cloud) (24), wherein the processed data is indicated to the rider/driver of the EV (10) through a display unit present in the dashboard (26) of the EV (10). In an embodiment, the display unit may be an interactive display unit. In another embodiment, the display unit may be a non-interactive display unit.
[0042] Embodiments of the present disclosure relate to automotive technology. In particular, the present disclosure provides a connector pair assembly, incorporating floatable slots that is self-adjusted while connecting with conductive pins, thereby enabling seamless connections between vehicular components.
[0043] Various embodiments of the present disclosure will be explained in detail with respect to FIGs. 2A-2D.
[0044] FIGs. 2A-2C illustrate schematic views of a connector pair assembly (200) for vehicular components, in accordance with embodiments of the present disclosure.
[0045] Referring to FIGs. 2A-2C, the connector pair assembly (200) may be used to connect two or more vehicular components. The vehicular components may be, but not limited to a battery, a motor, a motor controller, and the like. The connector pair assembly (200) may be configured to facilitate transmission of signals between different vehicular components. In an embodiment, the connector pair assembly (200) may include a first connector (202) and a second connector (204). In an embodiment, the first connector (202) may be a male connector and the second connector (204) may be a female connector. The first connector (202) may include conductive elements (202A) (e.g., connective pins). The conductive elements (202A) may include a first end (208A) and a second end (208B) (e.g., a male terminal).
[0046] In an embodiment, the second connector (204) may include a first section (204A) and a second section (204B). The second section (204B) may be configured with floatable slots (204C) and cables (222). The cables (222) may include a first portion (222A) and a second portion (222B). The first portion (222A) of the cables (222) may be disposed in the first section (204A) of the second connector (204), and the second portion (222B) of the cables (222) may be disposed in the second section (204B) and connected to a rear end of the floatable slots (204C) in the second section (204B). In an embodiment, the first portion (222A) of the cables (222) may be surrounded with a sealing element (224). In an embodiment, the first portion (222A) of the cables (222) and the sealing element (224) may be potted using the potting material (206). In an embodiment, the second portion (222B) of the cables (222) may facilitate an electrical connection between the conductive elements (202A) and the floatable slots (204C). The first portion (222A) of the cables (222) may be connected to an external vehicular component. For example, if the first connector (202) is integrated within the battery, the second connector (204) may be externally connected to the first connector (202) to facilitate the transmission of the signals between the battery and any other vehicular components such as, but not limited to the motor controller, the motor, and the like.
[0047] In an embodiment, the floatable slots (204C) may be configured with a wire gasket (220), an insulation crimp barrel (218), and a wire crimp barrel (216). In an embodiment, Ingress Protection (IP) ratings may be enabled by encapsulating a crimp interface (e.g., the insulation crimp barrel (218), and the wire crimp barrel (216)), a terminal interface (e.g., female terminals (204D), the male terminals (208B)), and a wire interface (e.g., the cables (222)). In an embodiment, the wire gasket (220) may be a component that provides a seal or insulation around the cables (222). The wire gasket (220) may prevent an entry of moisture, dust, or other contaminants into the electrical connections. The wire gasket (220) may enhance a secure and protected environment for the cables (222). In an embodiment, the insulation crimp barrel (218) may be a tubular component that is designed to secure and insulate the cables (222) within the second connector (204). The insulation crimp barrel (218) may typically involve crimping or compressing a barrel around an insulation of the cables (222), thereby creating a secure mechanical connection while providing insulation to prevent electrical contact with surrounding components. In an embodiment, the wire crimp barrel (216) may be, for example, a cylindrical component that is designed to secure the cables (222) within the second connector (204). However, in this case, the crimping may be applied to a metal part of the cables (222), thereby enhancing a reliable electrical connection between the vehicular components. In an embodiment, the floatable slots (204C) may be configured with a predefined diameter to receive the second end (208B) of the conductive elements (202A). The diameter may be 0.64 square millimetres but not limited thereto.
[0048] In an embodiment, when the first connector (202) and the second connector (204) are connected with each other, the floatable slots (204C) may be self-adjusted to connect with the second end (208B) of the conductive elements (202A) due to a rigid configuration of the first section (204A) of the second connector (204) and the first end (208A) of the first connector (202). For example, if the potting material (206) is potted on the first section (204A) and the first end (208A), the slots (204C) in the second section (204B) of the second connector (204) may be floated. These floatable slots (204C) may be self-adjusted to connect with the second end (208B) of the conductive elements (202A) when the first connector (202) is intent to connect with the second connector (204). In exemplary embodiments, referring to FIG. 2C, in the second connector (204), the potting material (206) may be potted above a line (228).
[0049] In exemplary embodiments, referring to FIG. 2B, the wire gasket (220) on the second connector (204) may be positioned on the cables (222) instead of directly positioning on the female terminals (204D). This may enhance that the female terminals (204D) of the second connector (204) remains flexible since the gasket member (212) acts as a pivot point (226). The pivot point (226) may distinctly demarcate a rigid portion located above the pivot point (226) from the floatable slots (204C) positioned below the pivot point (226). This pivotal point (226) may serve as a critical boundary, establishing a clear separation between the rigid portion and the floatable slots (204C) within the connector pair assembly (200). Conversely, the male terminals (208B) may be rigid due to an extension of the potting to the gasket member (212). During a mating process, the male side (e.g., the conductive elements (202A)) may remain stationary, while the flexible female side (e.g., the floatable slots (204C)) may have an ability to move. This flexibility allows the female terminals (204D) to adjust and align with the male terminal (e.g., 208B) facilitating a successful connection. In exemplary embodiments, the first connector (202) may be the female connector and the second connector (204) may be the male connector.
[0050] FIG. 2D illustrates a schematic view of the connective elements (202A), in accordance with embodiments of the present disclosure.
[0051] Referring to FIG. 2D, the first connector (202) may include the conductive elements (202A). The conductive elements (202A) may include the first end (208A) and the second end (208B). In an embodiment, the first end (208A) of the conductive elements (202A) may include a Printed Circuit Board (PCB) header (210) and a solder node (214). In an embodiment, the PCB header (210) may include a gasket member (212). The solder node (214) may be configured on a distal part of the first end (208A). In an embodiment, the solder node (214) may connect with an electronic element integrated within the vehicular component (e.g., the battery, the motor, the motor controller, and the like). In an embodiment, the PCB header (210) and the solder node (214) may be potted using the potting material (206). The solder node (214) may be soldered to the electronic element using a Soldered Post Mount (SPM). The potting material (206) may extend to the gasket member (212), thereby imparting rigidity to the PCB header (210) within the first connector (202).
[0052] In exemplary embodiments, when the floatable slots (204C) are connected to the second end (208B) of the conductive elements (202A), the gasket member (212) may be attached to an outer housing of the second section (204B). In an embodiment, the PCB header (210) may compress the gasket member (212) when the floatable slots (204C) are connected to the second end (208B) of the conductive elements (202A), thereby effectively creating a sealing function.
[0053] In this application, unless specifically stated otherwise, the use of the singular includes the plural and the use of “or” means “and/or.” Furthermore, use of the terms “including” or “having” is not limiting. Any range described herein will be understood to include the endpoints and all values between the endpoints. Features of the disclosed embodiments may be combined, rearranged, omitted, etc., within the scope of the disclosure to produce additional embodiments. Furthermore, certain features may sometimes be used to advantage without a corresponding use of other features.
[0054] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The scope of the disclosure is determined by the claims that follow. The disclosure is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the disclosure when combined with information and knowledge available to the person having ordinary skill in the art.
ADVANTAGES OF THE PRESENT DISCLOSURE
[0055] The present disclosure provides a connector pair assembly incorporating with floatable slots that adapt to variations in pin positions, accommodating minor misalignments or movements during the connection process.
[0056] The present disclosure provides a connector pair assembly that potted both a male connector and a female connector to create a sealed environment, thereby reducing a risk of water entry into the connector pair assembly.

List of References:
Components Referral Numerals
First connector 202
Conductive elements 202A
Second connector 204
First section 204A
Second section 204B
Floatable slots 204C
Potting material 206
First end 208A
Second end 208B
PCB header 210
Gasket member 212
Solder node 214
Wire crimp barrel 216
Insulation crimp barrel 218
Wire gasket 220
Cables 222
First portion 222A
Second portion 222B
Sealing element 224
, Claims:1. A connector pair assembly (200) for vehicular components, comprising:
a first connector (202) comprising one or more conductive elements (202A) having a first end (208A) and a second end (208B), wherein the first end (208A) is potted using a potting material (206); and
a second connector (204) comprising a first section (204A) and a second section (204B), wherein the first section (204A) is potted using the potting material (206) and the second section (204B) is configured with one or more floatable slots (204C), wherein each of the one or more floatable slots (204C) is self-adjusted to connect with the second end (208B) of each of the one or more conductive elements (202A) of the first connector (202).
2. The connector pair assembly (200) as claimed in claim 1, wherein the first end (208A) of each of the one or more conductive elements (202A) comprises:
a Printed Circuit Board (PCB) header (210) comprising a gasket member (212); and
a solder node (214) on a distal part of the first end (208A), wherein the solder node (214) is connected with an electronic element integrated within a vehicular component.
3. The connector pair assembly (200) as claimed in claim 1, wherein a PCB header (210) and a solder node (214) are potted using the potting material (206).
4. The connector pair assembly (200) as claimed in claim 1, wherein a gasket member (212) is attached to an outer housing of the second section (204B) when each of the one or more floatable slots (204C) is connected to the second end (208B) of each of the one or more conductive elements (202A) of the first connector (202).
5. The connector pair assembly (200) as claimed in claim 1, wherein the second connector (204) is configured with one or more cables (222), wherein each of the one or more cables (222) facilitate an electrical connection corresponding to each of the one or more floatable slots (204C).
6. The connector pair assembly (200) as claimed in claim 5, wherein a first portion (222A) of the one or more cables (222) are surrounded with a sealing element (224), and wherein a second portion (222B) of each of the one or more cables (222) facilitates the electrical connection between each of the one or more conductive elements (202A) and each of the one or more floatable slots (204C).
7. The connector pair assembly (200) as claimed in claim 5, wherein a first portion (222A) of the one or more cables (222) is connected to another vehicular component, and wherein the first portion (222A) of each of the one or more cables (222) and a sealing element (224) are potted using the potting material (206).
8. The connector pair assembly (200) as claimed in claim 5, wherein a first portion (222A) of the one or more cables (222) is disposed in the first section (204A), and wherein a second portion (222B) of each of the one or more cables (222) is disposed corresponding to a rear end of each of the one or more floatable slots (204C) in the second section (204B).
9. The connector pair assembly (200) as claimed in claim 1, wherein the one or more floatable slots (204C) are configured with a wire gasket (220), an insulation crimp barrel (218), and a wire crimp barrel (216).
10. The connector pair assembly (200) as claimed in claim 1, wherein each of the one or more floatable slots (204C) are configured with a predefined diameter to receive the one or more second end (208B) of each of the one or more conductive elements (202A) of the first connector (202).