Unitary Battery Connector Carrier With Flexible Hinges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery connector systems for prismatic battery modules face challenges such as time-consuming connections, alignment difficulties, and issues with attaching sensing wires and thermistors due to threaded posts or bolts, and the complexity of plastic carriers in welded configurations.
Innovation Solution
A battery connector system featuring a unitary carrier housing with integral cell connecting sections and cover portions, including bus bar and wire trace cavities, utilizing flexible hinges for alignment and snap-in bus bar assemblies, and a thermistor assembly with a spring mechanism for proximity to battery cells, simplifying the connection process and improving alignment and attachment of sensing wires and thermistors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded posts or bolts are used to connect bus bars to battery terminals, then the connection can be made, but the connection process becomes time-consuming and may result in over or under torque, or cross threading
Solution Approach 1:
The patent replaces the threaded mechanical fastening system with a welding process that joins the bus bar directly to the battery terminals. This substitution eliminates the need for bolts and nuts, thereby increasing assembly speed while maintaining connection reliability through proper welding techniques.
Solution Approach 2:
The invention extracts and removes the threaded fastening components (bolts, nuts, and threading features) from the connection system. By eliminating these components entirely and using direct welding, the patent simplifies the connection process and improves productivity without compromising reliability.
2Ease of manufacture
If conventional plastic carriers with multiple pieces are used to hold bus bars, then the bus bars can be contained, but alignment becomes difficult and the structure becomes complex
Solution Approach 1:
The patent merges multiple separate plastic carrier components into a single integrated carrier structure. This unified design simplifies the overall structure, reduces the number of parts, and improves alignment accuracy while maintaining the ability to contain and organize bus bars effectively.
Solution Approach 2:
The integrated carrier is designed to perform multiple functions simultaneously: it contains the bus bars, provides alignment features, and incorporates mounting points for thermistors and voltage sensing wires. This multi-functionality reduces the need for separate components and simplifies the overall assembly.
3Ease of manufacture
If conventional multi-piece plastic carriers are used, then the bus bars can be held, but attaching sensing wires and thermistors becomes difficult
Solution Approach 1:
The patent combines the bus bar holder, wire attachment points, and thermistor mounting features into a single integrated carrier structure. This merging of features into one component simplifies the attachment process for sensing wires and thermistors while maintaining effective bus bar holding capability.
4Strength
If rigid carrier structures are used, then the bus bars are securely held, but alignment with battery cells becomes difficult due to tolerances
Solution Approach 1:
The patent incorporates flexible elements into the carrier structure, such as flexible arms or spring-loaded components, that can adapt to variations in battery cell positions. These flexible features maintain secure holding of the bus bars while providing the necessary alignment flexibility to accommodate manufacturing tolerances.
Solution Approach 2:
The carrier design transitions from a completely rigid structure to one that includes dynamic, movable components. These dynamic elements can adjust their position or orientation to accommodate alignment variations while maintaining firm contact with the bus bars, thereby providing both security and adaptability.
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 solution provides a more efficient, cost-effective, and simplified method for connecting battery cells, reducing assembly time and improving the reliability of connections while accommodating variations in battery cell placement and tolerances.
Implementation Method 1
a thermistor assembly with a spring mechanism for proximity to battery cells
Implementation Method 2
utilizing flexible hinges for alignment
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A battery connector system for connecting battery cells of a battery module includes a carrier assembly (102) having a carrier housing (104) and a plurality of bus bar assemblies held by the carrier housing. The bus bar assemblies are configured to connect corresponding battery cell terminals of adjacent battery cells. The carrier assembly includes a plurality of cell connecting sections (150) each holding a corresponding bus bar assembly and cover portions (270) associated with the cell connecting sections. The carrier housing has a unitary construction with each of the cell connecting sections and cover portions being integral.