Integrated Battery Connector Terminal With Elastic Arms
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Solution Overview
Problem
The assembly of traditional battery connectors is challenging due to the non-integrated components of the conductive terminal, which includes a metal pin, compression spring, and conductive base, leading to difficulties in assembly and electrical connection stability.
Innovation Solution
The design incorporates an elastic connecting portion with parallel elastic arms, a bendable contact portion, and a fastening portion with a passive contact arm, forming a spring-like structure that allows for efficient compression and secure contact, reducing the size and manufacturing cost of the battery connector while ensuring reliable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate components (metal pin, compression spring, conductive base) are used, then electrical connection can be achieved, but assembly time increases and assembly difficulty increases due to bouncing during assembly
Solution Approach 1:
The patent combines the metal pin, compression spring, and conductive base into a single integrated conductive terminal component. This merging eliminates the need for separate assembly of multiple parts, directly reducing assembly time while maintaining the electrical connection function through the integrated structure that includes a contact portion, elastic portion, and connecting portion.
Solution Approach 2:
The integrated conductive terminal is segmented into functional portions (contact portion, elastic portion, connecting portion) that perform different functions. This segmentation within integration allows each portion to be optimized for its specific function while avoiding the assembly issues of separate components.
2Reliability
If traditional separate components are used, then electrical connection is achieved, but assembly difficulty increases due to bouncing of metal pin and conductive base during assembly
Solution Approach 1:
By merging all components into a single integrated conductive terminal, the patent eliminates the bouncing problem that occurs when separate metal pin and conductive base components are assembled together. The integrated structure ensures proper alignment and connection without assembly bouncing, significantly improving assembly ease.
3Productivity
If integrated conductive terminal is used, then assembly time is reduced and assembly ease is improved, but device complexity increases due to the spring-like structure design
Solution Approach 1:
The patent uses an elastic portion with branch arms that can bend and deform elastically to provide spring-like functionality. This flexible structure replaces the traditional compression spring while maintaining the necessary elastic properties, and can be integrated into a single component, thereby reducing device complexity compared to multiple separate components.
Solution Approach 2:
The patent changes the physical state and properties of the conductive terminal by making it an integrated elastic structure rather than separate rigid components. This parameter change allows the structure to provide both mechanical connection and electrical conduction in a single component, improving productivity while managing complexity through material and structural optimization.
4Reliability
If traditional components are used, then electrical connection is achieved, but manufacturing cost increases due to multiple separate parts
Solution Approach 1:
The patent merges multiple components (metal pin, compression spring, conductive base) into a single integrated conductive terminal, which can be manufactured as one piece using processes like stamping or injection molding. This significantly reduces manufacturing cost by eliminating the need to produce, manage inventory, and assemble multiple separate parts, while maintaining reliable electrical connection.
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 enables a compact, lightweight battery connector with enhanced electrical contact reliability and reduced manufacturing costs, allowing for efficient use of space and improved normal force during electricity transmission.
Implementation Method 1
The elastic arms are parallel and substantially aligned along a transversal direction... capable of being compressed and providing sufficient elastic force
Data Source
AI summary
A battery connector includes an insulation housing and conductive terminals. The insulation housing has slots, and the conductive terminals are held in the slots. Each conductive terminal includes an elastic connecting portion, a contact portion, and a fastening portion. The elastic connecting portion includes elastic arms parallel and substantially aligned along a transversal direction and connecting portions formed at two ends of each of the elastic arms. The contact portion includes a bendable contact portion extended forwardly from the elastic connecting portion and then folded and extended backwardly and an active contact arm formed at an end portion of the bendable contact portion. The fastening portion includes a bent portion extended backwardly from the elastic connecting portion and then folded and extended forwardly and a passive contact arm formed at an end portion of a bent portion and aligned with the active contact arm.