Battery Pack Connector Module With Guided Misalignment-Tolerant Coupling
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Solution Overview
Problem
Existing connector modules for battery packs face challenges in precise alignment and coupling, leading to frequent damage and connection failures due to misalignment during assembly.
Innovation Solution
The connector module incorporates a coupling guide rib that extends to guide the coupling position, a fastening part that allows movement within a predetermined range, and magnetic attraction to ensure precise alignment and secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment of connector modules is used, then assembly simplicity is maintained, but alignment precision deteriorates leading to frequent damage
Solution Approach 1:
A coupling guide rib is introduced as an intermediary element between the connector module and the receptacle. The guide rib extends from the connector module and fits into a receiving groove on the receptacle, automatically guiding the connector to the correct position during assembly. This mechanical intermediary ensures precise alignment without requiring complex external alignment tools or procedures.
Solution Approach 2:
The coupling guide rib is pre-positioned on the connector module before assembly. The rib's geometry is designed in advance to match the receiving groove, so that when the connector is brought near the receptacle, the guide rib automatically engages with the groove and guides the connector into precise alignment. This preliminary positioning structure eliminates the need for manual adjustment during assembly.
2Manufacturing precision
If rigid fixed positioning is used, then alignment precision is improved, but ease of operation deteriorates due to difficulty in insertion
Solution Approach 1:
The coupling part is designed with dynamic characteristics, allowing it to move elastically in the vertical direction within a predetermined range. When the connector is inserted, the coupling part can deform to accommodate slight misalignments or variations in insertion force, then returns to its original position to maintain precise coupling. This dynamic flexibility makes insertion easier while preserving alignment precision.
Solution Approach 2:
The coupling part incorporates flexible elements that can deform elastically. These flexible components allow the connector to be inserted with varying forces and angles, absorbing the impact through controlled deformation. Once inserted, the flexible elements return to their original shape, ensuring the connector maintains precise positioning without requiring rigid, difficult-to-insert structures.
3Manufacturing precision
If coupling guide rib is added, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The coupling guide rib is merged with the connector module as an integrated component rather than a separate attachment. The rib is formed as part of the connector's housing or body structure, combining the functions of structural support and alignment guidance into a single unified element. This integration minimizes the increase in device complexity while maintaining the alignment precision benefits.
Solution Approach 2:
The coupling guide rib serves multiple functions: it provides structural support for the connector, guides the insertion direction, ensures precise alignment with the receptacle, and protects the electrical contacts during assembly. By combining multiple functions into a single element, the overall device complexity is minimized while achieving precise coupling positioning.
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
This configuration enhances the durability and convenience of the connector module by preventing damage from misalignment and ensuring reliable electrical connections.
Implementation Method 1
a coupling part including a coupling guide rib, wherein the coupling guide rib extends toward the external connector module, is inserted into the receiving groove when the external connector module is connected to the connector module, and is configured to guide a coupling position of the connector module
Implementation Method 2
magnetic attraction to ensure precise alignment and secure coupling
Data Source
AI summary
The present disclosure discloses a connector module with improved convenience in use and durability. The connector module has at least one receptacle and a receiving groove having an inner space, is configured to be connected to an external connector module provided in an external device, and is provided in an internal device. The connector module includes at least one plug configured to be coupled to the receptacle for electrical connection with the receptacle, a coupler including a coupling guide rib, which extends toward the external connector module, inserted into the receiving groove when the external connector module is connected to the connector module, and is configured to guide a coupling position of the connector module, and a fastener coupled to the coupler such that the coupler moves in a predetermined distance range and configured such that a portion of the fastener is fixed to the internal device.