Battery Charging Connector Segmented Pins
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Solution Overview
Problem
Existing electrical connectors for charging lithium storage batteries face issues with imprecise potential difference measurements due to contact resistance, mechanical weakness, and misalignment, leading to potential self-discharge or explosion risks during the charging process.
Innovation Solution
An electrical connector with a conductive bush and multiple copper pins extending from a common base, providing a larger contact surface and improved mechanical strength, along with electrical isolation and elastic means for precise measurements and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single contact point connector is used for charging battery cells, then the device complexity is reduced, but the measurement precision of potential difference deteriorates due to contact resistance
Solution Approach 1:
The connector is divided into multiple independent contact elements (at least two contact elements) instead of a single contact point. Each contact element can independently contact different points on the battery electrode, allowing separate measurement contacts that bypass the charging current path, thereby eliminating contact resistance interference in potential difference measurements
Solution Approach 2:
The invention introduces separate measurement contact elements that act as intermediaries between the charging system and the battery cell. These dedicated measurement contacts provide a separate electrical path for voltage sensing that does not carry charging current, thus serving as an intermediary that isolates the measurement function from the power transfer function
2Manufacturing precision
If a small contact surface connector is used, then the alignment tolerance requirements are reduced, but the mechanical strength and contact reliability deteriorate
Solution Approach 1:
The contact surface is segmented into multiple discrete contact elements distributed across the connector face. This segmentation allows each individual contact element to be small and easy to align, while the collective arrangement provides substantial total contact area and mechanical strength, resolving the contradiction between small contact size and alignment tolerance
3Measurement precision
If multiple contact elements are used for precise measurement, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
Multiple contact elements are merged into a single integrated connector body structure. The connector housing combines both power transfer contacts and measurement contacts in one unified component, eliminating the need for separate measurement devices and reducing overall system complexity despite the multiple contact points
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
The connector enables precise electrical measurements and improved mechanical strength, reducing the risk of misalignment and self-discharge, while allowing for safe and reliable charging of lithium storage batteries.
Implementation Method 1
the electrical connector (1) comprises elastic means (21), housed within the cavity (3) of the bush (2), acting on the electrical contacting element (7) in order to push the free ends (12) of the pins (10) towards the contact surface (11)
Implementation Method 2
a bush (2) made of conductive material, susceptible of being power supplied by an electrical power source... at least one electrical contacting element (7) made of conductive material, such as copper
Data Source
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AI summary
Electrical connector for an apparatus for charging electric storage battery cells, which comprises a bush (2) power supplied by an electrical power source and provided with an end wall (4) intended to abut against an electrode of a cell of an electric storage battery in order to power supply it. The electrical connector also comprises an electrical contacting element (7) mounted inside the bush (2) and provided with a plurality of pins (10) which traverse corresponding through holes, electrically isolated, of the end wall (4) of the bush (2) in order to abut against the electrode of the cell so to carry out electrical measurements.