Battery Pack Connector With Clamping Protrusions For High Current
Solution Overview
Problem
Existing battery pack connectors face challenges in securely and efficiently connecting wires to battery cells or protective circuit modules, particularly in ensuring reliable coupling and safety during high-current operations.
Innovation Solution
A connector design featuring a first connecting member for attachment to a battery cell or protective circuit module and a second connecting member with protrusions for clamping a wire, along with a clip portion for securing the connection, allowing for easy welding and enhanced coupling force, even under high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector design is used to connect wires to battery cells, then the connection can be established, but the coupling force is insufficient under high current conditions and the connection may become loose or unsafe
Solution Approach 1:
The connector is divided into two separate members: a first connecting member that connects to the battery cell and a second connecting member that connects to the wire. This segmentation allows each member to be optimized for its specific function, with the second member featuring protrusions designed specifically for clamping the wire with sufficient force while the first member maintains connection to the battery cell.
Solution Approach 2:
The second connecting member is folded onto the first connecting member about a connecting region, creating a three-dimensional coupled structure. This folding arrangement allows the protrusions to wrap around and clamp the wire from multiple directions, significantly enhancing the coupling force and connection reliability under high current conditions.
2Strength
If a secure connection is achieved through complex connector design, then connection strength improves, but manufacturing complexity and difficulty increase
Solution Approach 1:
By dividing the connector into two separate members that can be manufactured independently, each component can be produced using simpler, more standardized processes. The first connecting member is designed for battery cell connection while the second member with protrusions is designed for wire clamping, allowing specialized manufacturing techniques to be applied to each part separately.
Solution Approach 2:
The connecting region acts as an intermediary that couples the first and second connecting members together through folding. This intermediate structure enables the transmission of mechanical force and electrical connection while maintaining manufacturing simplicity, as the folding operation is a straightforward forming process that can be easily integrated into production.
3Productivity
If welding is performed before connecting the wire, then the battery cell connection is established, but access to welding areas may be blocked by the wire and connector structure
Solution Approach 1:
The connector design allows for flexible sequencing of assembly operations. The second connecting member with its protrusions can be positioned and folded onto the first member after welding, or the welding can be performed on exposed surfaces before folding. This dynamic arrangement enables manufacturers to optimize the assembly sequence based on specific production requirements while maintaining both welding accessibility and connection security.
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 provides a secure, efficient, and safe connection between wires and battery cells or protective circuit modules, ensuring reliable operation and improved working safety by maintaining the coupling force even when solder melts due to high current.
Implementation Method 1
the second connecting member is folded onto the first connecting member about the connecting region
Implementation Method 2
The second connecting member may comprise first and second protrusions for clamping the wire onto the second connecting member
Implementation Method 3
the clip portion being arranged to engage with a top surface of the second connecting member to hold the second connecting member on the first connecting member
Implementation Method 4
Alternatively or in addition solder may be applied to the first and second protrusions and the wire
Data Source
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AI summary
Embodiments of the present invention provide a connecting tab of a battery pack, which allows a wire to be firmly coupled to a battery cell or a protective circuit module, a coupling structure between the connecting tab and a wire, and coupling method thereof. In one embodiment of the present invention, the connecting tab coupled to a battery cell or a protective circuit module includes a first conductive layer electrically connected to the battery cell or the protective circuit module, and a second conductive layer formed on the first conductive layer and coupled to a wire. The second conductive layer may include a pair of coupling protrusions upwardly protruding for connection of the wire. A solder may further be formed on the coupling protrusions and the wire.