Power Battery Connector With Bent Segments For Vibration Resistance
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Solution Overview
Problem
Existing power battery module connectors, such as braided wires and lamination guide plates, face issues with high contact resistance, limited flexibility, and high manufacturing costs, and are not suitable for three-dimensional deformation, leading to reliability and space occupancy problems.
Innovation Solution
A connector design with a main connection sheet divided into two segments, each with a fixing sheet forming angles greater than 0 degrees and less than 180 degrees, allowing for flexibility in three directions, replacing braided wires and reducing contact resistance, and featuring a simple structure for low cost and efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If braided wires are used to connect power battery modules, then flexibility is improved, but contact resistance increases and reliability decreases under vibration conditions
Solution Approach 1:
The connector is divided into a first connection segment and a second connection segment, with the second segment bent and turned over to create a multi-directional flexible structure that maintains electrical connection while accommodating vibrations and deformations
Solution Approach 2:
The connector transitions from a single-plane flat or arch shape to a three-dimensional structure with bends in multiple directions, enabling flexibility in at least three directions while maintaining structural integrity and low contact resistance
2Stability of the object's composition
If lamination guide plates with multiple layers of copper or aluminum foils are used, then connection stability is improved, but contact resistance increases and manufacturing complexity increases
Solution Approach 1:
The single-layer connector structure is segmented into first and second connection segments with different orientations, providing both stability and flexibility without requiring multiple stacked layers of foils
Solution Approach 2:
The connector uses a single-layer design that combines structural stability with electrical conductivity, eliminating the need for multiple layers of copper or aluminum foils while maintaining connection reliability
3Ease of manufacture
If flat or arch connection sheets are used, then manufacturing simplicity is improved, but flexibility and vibration resistance decrease
Solution Approach 1:
The connector evolves from a two-dimensional flat or arch shape to a three-dimensional structure with the second connection segment bent and turned over, enabling flexibility in multiple directions while maintaining manufacturing simplicity through a single-layer design
Solution Approach 2:
The connector incorporates dynamic flexibility through bends in at least three directions, allowing it to adapt to vibrations and three-dimensional deformations while maintaining electrical connection, unlike static flat or arch designs
4Reliability
If the second connection segment is bent and turned over to create multi-directional flexibility, then vibration-resistant reliability is improved, but structural complexity increases
Solution Approach 1:
The connector is segmented into two main sections (first and second connection segments) with a simple bending relationship, creating multi-directional flexibility without requiring complex multi-component assemblies
Solution Approach 2:
The first and second connection segments are merged into a single integrated structure where the second segment is bent and turned over, combining flexibility and electrical connection functions in one piece rather than multiple separate components
Data Source
Figure 1~2
Figure 3~4
AI summary
A connector (100) for power batteries, a power battery module, a power battery pack and a vehicle are provided. The connector (100) includes a main connection sheet, a first fixing sheet (10) and a second fixing sheet (20), in which the main connection sheet includes first and second segments (30,40) in a longitudinal direction, the second connection segment (40) is bent and turned over to be located above the first connection segment (30), the first fixing sheet (10) is connected with a side edge of the first connection segment (30) and a first predetermined angle is formed between the first fixing sheet (10) and the first connection segment (30), the second fixing sheet (20) is connected a side edge of the second connection segment (40) and a second predetermined angle is formed between the second fixing sheet (20) and the second connection segment (40), each of the first and second predetermined angles is larger than 0 degree and less than 180 degrees. The connector, the power battery module, the power battery pack and the vehicle present the advantages of simple structure, high vibration resistance and easy assembly.