Battery Pack Clip Connector With Multi-Point Pin Contact
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Solution Overview
Problem
Conventional battery pack connectors suffer from poor contact due to a single contact point, leading to increased contact resistance, heat generation, and potential device malfunction, necessitating tight manufacturing tolerances that are difficult to maintain.
Innovation Solution
A battery pack connector with multiple contact points, including a clip portion, contact arm, and optional contact plate, designed to maintain contact through varying distances and elastic properties, ensuring reliable electrical connection despite manufacturing defects or repeated use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single contact point is used in the connector, then the connector structure is simple, but poor contact occurs due to contact point widening during frequent insertion and separation
Solution Approach 1:
The connector is divided into multiple contact points (first contact point formed by clip portion, second contact point formed by contact arm, and third contact point formed by contact plate) instead of using a single contact point. This segmentation ensures that if one contact point widens or fails, other contact points maintain the electrical connection, thereby improving contact reliability while keeping each individual contact point structure relatively simple
2Reliability
If manufacturing tolerance is set to be very small to prevent poor contact, then contact reliability improves, but manufacturing difficulty increases
Solution Approach 1:
Different contact points are designed with different local characteristics and functions. The clip portion forms a first contact point, the contact arm forms a second contact point with varying distance to the device pin, and the contact plate forms a third contact point at the distal end. This local quality differentiation allows each contact point to compensate for others, reducing the need for extremely tight manufacturing tolerances while maintaining high contact reliability
3Device complexity
If a single contact point is used, then the connector design is simple, but contact resistance increases and heat is generated during frequent use
Solution Approach 1:
The electrical connection is segmented into multiple parallel contact paths through the clip portion, contact arm, and contact plate. This segmentation distributes the electrical current across multiple contact points, reducing contact resistance and heat generation at each individual contact point, thereby eliminating harmful thermal effects while maintaining simple overall connector design
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 multi-point design ensures consistent contact even with one point widening, reducing manufacturing defects and preventing device malfunctions by maintaining electrical connection through alternative contact points.
Implementation Method 1
the contact arm being configured to form a second contact point having a distance to the device pin varying in inverse proportion to a distance to the device pin at the first contact point
Implementation Method 2
each of the clip portion and the contact arm may be elastic such that insertion and separation of the device pin are easily performed
Data Source
AI summary
Discussed is a battery pack including: a plurality of battery cells; a case configured to receive the plurality of battery cells therein; a connector configured to electrically connect the battery pack to a device; and a printed circuit board (PCB) configured to control operation of the battery pack, the PCB being located inside or outside the case, and the connector being coupled to the PCB, wherein the connector comprises: a clip portion configured to form a first contact point at which the connector electrically contacts a device pin inserted into the connector; and a contact arm having one side connected to the clip portion, the contact arm being configured to form a second contact point having a distance to the device pin varying in inverse proportion to a distance to the device pin at the first contact point.