Battery Pack Connector Support Structure for Stable Pin Contact

Solution Overview

Problem

Poor contact between the connector and device pin due to deformation of the connector occurs during repeated insertion and separation, leading to increased contact resistance and potential device malfunction.

Innovation Solution

A battery pack design incorporating a support member around the connector, comprising a pair of bars or bars with protrusions, to restrict deformation and maintain stable contact with the device pin, using an elastic material to ensure consistent electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the connector is designed without additional support structures, then the device complexity is reduced, but the connector deforms during repeated insertion and separation, causing poor contact

Engineering Contradiction:

Improvecontact reliabilityVSAvoidconnector structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The support member is divided into multiple bars (first bar, second bar, third bar, fourth bar) that are distributed around the connector. Each bar provides localized support at critical positions, preventing deformation without requiring a complete encasement structure. This segmented approach maintains reliability while minimizing added complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support member acts as an intermediary structure between the connector and the external environment. It mediates the mechanical stresses during insertion and separation by providing rigid support through its bars, preventing the connector from deforming while maintaining electrical isolation through the insulating material.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the connector structure is simplified, then the manufacturing cost is reduced, but contact resistance increases due to poor contact from connector deformation

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnector manufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The support member is divided into multiple bars (first bar, second bar, third bar, fourth bar) that are distributed around the connector. Each bar provides localized support at critical positions, preventing deformation without requiring a complete encasement structure. This segmented approach maintains reliability while minimizing added complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support member acts as an intermediary structure between the connector and the external environment. It mediates the mechanical stresses during insertion and separation by providing rigid support through its bars, preventing the connector from deforming while maintaining electrical isolation through the insulating material.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the support member is positioned close to the connector, then the prevention effect against deformation is enhanced, but the risk of interference with device pin insertion increases

Engineering Contradiction:

Improveconnector stabilityVSAvoiddevice pin insertion ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The support member's bars are strategically positioned at specific locations around the connector rather than forming a continuous enclosure. The first and second bars support one side of the connector, while the third and fourth bars support the other side, providing localized support exactly where deformation occurs during insertion and separation.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of providing complete 360-degree support around the connector, the support member uses a partial configuration with four strategically placed bars. This partial support is sufficient to prevent deformation at critical points while leaving enough space for device pin insertion, avoiding excessive action that would interfere with operation.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS12614807B2Battery pack including member capable of preventing poor contact with device

Publication Date: 2026.04.28 LG ENERGY SOLUTION LTD

AI summary

Discussed is a battery pack which may include a plurality of battery cells, a pack case configured to receive the plurality of battery cells therein, the pack case including a lower case and an upper cover, a connector located in the pack case, the connector being configured to electrically connect the battery pack to a device, and a printed circuit board (PCB) in the pack case, the connector being coupled to one surface of the PCB, wherein the upper cover includes a plurality of pin insertion ports configured to allow a device pin to be inserted into the connector therethrough, and wherein the upper cover is provided at an inside thereof with a support member located adjacent the connector, the support member being configured to restrict deformation of the connector.