Modular Battery Connecting Assembly with Positioning Member
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Solution Overview
Problem
The existing battery connection methods for electric cars and hybrid cars are cumbersome and costly, particularly when the number of electric cells changes, as they require multiple molds and risk short circuits due to incorrect assembly positions.
Innovation Solution
A battery connecting assembly with resin units and positioning members that define the relative positions of coupling units, preventing incorrect assembly and short circuits by ensuring accurate alignment of connecting members between electric cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a battery connection plate with multiple connecting members integrally molded is used, then multiple connecting members can be mounted at once, but the mold size increases and manufacturing cost increases
Solution Approach 1:
The battery connection plate is divided into multiple detachable connection units, each accommodating a connecting member. These units can be assembled separately using smaller, less expensive molds and then connected together, eliminating the need for a single large expensive mold while still enabling simultaneous mounting of multiple connecting members.
Solution Approach 2:
The connection units are designed to be detachably connected, allowing the battery connection plate to be assembled in segments and configured for different numbers of electric cells. This dynamic assembly approach reduces initial mold investment while maintaining high mounting productivity.
2Adaptability or versatility
If the number of electric cells is changed, then battery configuration flexibility is improved, but new molds must be prepared increasing manufacturing cost
Solution Approach 1:
The battery connection plate consists of multiple identical or modular connection units that can be combined in different quantities. When the number of electric cells changes, the appropriate number of connection units are assembled together, eliminating the need for new molds and reducing manufacturing costs while maintaining configuration flexibility.
Solution Approach 2:
Each connection unit is designed with universal functionality to accommodate connecting members for different electric cell configurations. The same basic unit design can be used across various battery configurations by simply changing the number of units assembled, making the system adaptable without requiring new molds.
3Ease of operation
If battery connecting assemblies are installed line by line, then assembly flexibility is improved, but installation position errors may cause short circuits
Solution Approach 1:
Positioning protrusions and corresponding positioning recesses are provided on the connection units to create an asymmetric positioning mechanism. This ensures that connection units can only be assembled in the correct relative positions, preventing installation position errors that could cause short circuits while still allowing flexible line-by-line assembly.
Solution Approach 2:
The positioning protrusions and recesses act as intermediary elements between connection units, mediating their relative positions during assembly. These positioning features guide the connection units into correct alignment, ensuring reliable assembly without short circuits while maintaining operational flexibility.
Data Source
AI summary
A battery connecting assembly 20 includes a first coupling unit 21 having a plurality of individual units 20A each accommodating a connecting member 13, and configured by coupling the individual units 20A adjacent to each other; a second coupling unit 22 having a plurality of individual units 20A each accommodating a connecting member 13, and configured by coupling the individual units 20A adjacent to each other, and arranged side by side with the first coupling unit 21; and a positioning member 40 connected to the first coupling unit 21 and the second coupling unit 22 to position the first coupling unit 21 and the second coupling unit 22 relatively.