Battery Connector Module Fastening Structure for Stable FPC Assembly
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Solution Overview
Problem
The existing battery connection modules for vehicle-mounted power batteries are unstable due to the reliance on elastic clamps, leading to weak structural integrity, which can damage flexible circuit boards and affect the assembly of batteries, reducing the service life.
Innovation Solution
A battery connection module comprising a carrying tray, busbars, a flexible circuit board, a connector, and a connector box with multiple holding structures that securely position and prevent detachment of the connector, enhancing stability and assembly strength through cooperative mechanisms between the connector housing, connector box, and end plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If an elastic clasp is used to clamp the connector, then the connector can be held in place, but the connector becomes unstable under various forces (inserting, pulling, pushing, dragging, shaking)
Solution Approach 1:
The fastening base is divided into a first fastening base and a second fastening base that are separately arranged on the carrying tray. The first fastening base holds the connector while the second fastening base provides additional support. This segmentation distributes the mechanical loads and provides multiple independent fastening points, significantly improving both stability and strength compared to a single elastic clasp.
Solution Approach 2:
The connector is simultaneously fastened by both the first fastening base (with elastic clasp) and the second fastening base (with fastening components). This merging of multiple fastening mechanisms creates a composite fastening system that combines the advantages of elastic retention with positive mechanical locking, enhancing overall connector stability and structural strength.
2Ease of manufacture
If the fastening base is integrally connected to the carrying tray, then assembly is simplified, but the connector assembly becomes vulnerable to damage affecting the flexible circuit board, tray, and battery assembly
Solution Approach 1:
The fastening function is segmented into separate first and second fastening bases, which are independently mounted on the carrying tray. This segmentation isolates the connector fastening system from the main tray structure, so that fastening failures or connector movements do not directly transmit forces to the entire tray assembly, protecting the flexible circuit board and battery components.
Solution Approach 2:
The first and second fastening bases act as intermediary components between the connector and the carrying tray. These intermediaries absorb and distribute mechanical stresses, preventing direct force transmission from connector movements to the tray and sensitive components like the flexible circuit board, thereby improving reliability while maintaining assembly simplicity.
3Device complexity
If only elastic force is used to clamp the connector, then the structure remains simple, but the connector is not stable enough under operational forces
Solution Approach 1:
The fastening system is segmented into two independent fastening bases with different mechanisms. The first fastening base uses elastic force for simple retention, while the second fastening base introduces additional fastening components for mechanical locking. This segmentation allows the system to maintain simplicity where possible while adding complexity only where needed for enhanced stability.
Solution Approach 2:
The fastening system uses a composite approach combining elastic materials (elastic clasp) with rigid mechanical fastening components (fastening components in the second fastening base). This composite fastening mechanism leverages the advantages of both elastic retention and rigid locking to achieve high stability without excessive complexity.
Data Source
AI summary
A battery connection module of the present disclosure includes a carrying tray, a plurality of busbars, a flexible circuit board, a connector and a connector box. The flexible circuit board is provided to the carrying tray. The connector is provided at an end of the flexible circuit board, the connector includes a connector housing and a plurality of conductive terminals which are provided in the connector housing and electrically and mechanically connected to the flexible circuit board, the connector housing has a mating portion at a front end thereof, a base at a rear end thereof and a rear supporter protruding rearwardly from the base. The connector box is constructed to one end of the carrying tray and receives the connector, the connector box includes a bottom wall, two side walls and an upper opening which allows the connector to be assembled therein.