Battery Pack Connector Clip Structure Against Terminal Deformation
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Solution Overview
Problem
Connectors used in battery management systems suffer from permanent deformation and connection failures due to repeated insertion and removal, leading to unreliable electrical connections.
Innovation Solution
A connector design featuring elastically deformable clip terminal units and a terminal housing with a support structure that offsets insertion forces, including a third extension structure for heat dissipation and a locking protrusion for enhanced stability, to prevent permanent deformation and ensure reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the connector is repeatedly connected and disconnected, then the connector can be used multiple times, but the connection region becomes damaged or permanently deformed leading to connection failure
Solution Approach 1:
The patent introduces a resilient member that acts as a cushioning element between the connection terminal and the counterpart connector. This resilient member absorbs the impact and stress during repeated connection and disconnection operations, preventing permanent deformation of the connection terminal. The cushioning effect is built into the connector structure beforehand, allowing it to withstand multiple operations while maintaining connection reliability.
Solution Approach 2:
The patent changes the mechanical properties of the connection terminal by making it elastically deformable rather than rigid. The connection terminal is designed with specific elastic characteristics that allow it to flex during insertion and removal, absorbing stress without permanent deformation. This parameter change from rigid to elastic enables the connector to endure repeated operations while maintaining reliable electrical connection.
2Stability of the object's composition
If the connection terminal is made rigid for stable connection, then connection stability is improved, but resistance to deformation during repeated insertion and removal decreases
Solution Approach 1:
The patent transforms the connection terminal from a rigid structure to an elastically deformable one with optimized mechanical properties. The terminal is designed with specific elastic modulus and geometric characteristics that provide both stability during connection and flexibility to resist deformation during repeated operations. This parameter optimization allows the terminal to maintain stable electrical connection while withstanding mechanical stress.
Solution Approach 2:
The patent introduces dynamic characteristics to the connection terminal by making it capable of elastic deformation. Rather than being a static rigid structure, the terminal can dynamically adjust its shape during insertion and removal operations, absorbing mechanical energy through elastic deformation. This dynamic behavior enables the terminal to maintain stability during normal operation while resisting permanent deformation during repeated connections.
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 design significantly reduces the occurrence of permanent deformation and connection failures, maintaining reliable electrical connections and improving heat dissipation performance.
Implementation Method 1
a first clip terminal unit and a second clip terminal unit which are elastically deformable and contact a counterpart connection terminal
Implementation Method 2
a support portion extending from the connection portion and configured to be supported by the sidewall of the terminal housing
Implementation Method 3
a third extension structure bent and extending from the second extension structure so that at least a part of the support portion is supported by an inner surface of the side wall of the terminal housing
Data Source
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AI summary
A connector with increased durability is provided. A connector includes a mounting unit electrically connected to a battery management unit configured to manage voltages of a plurality of battery cells; a first clip terminal unit and a second clip terminal unit configured to be elastically deformable and to contact a counterpart connection terminal; and a terminal housing comprising a side wall configured to electrically insulate the first clip terminal unit and the second clip terminal unit from an outside, wherein each of the first clip terminal unit and the second clip terminal unit includes a connection portion having a part contacting a counterpart connection terminal inserted between the first clip terminal unit and the second clip terminal unit; and a support portion extending from the connection portion and configured to be supported by the sidewall of the terminal housing.