Battery Module Connector Mounting for Stable Jig Inspection
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Solution Overview
Problem
Existing battery modules face challenges in securely fixing connectors to the housing while minimizing contact area, which affects stability and compatibility with inspection jigs.
Innovation Solution
A connector design with a spaced bottom surface and side surfaces fixed to the housing using protruding portions and catching protrusions, along with an elastic hook, allows stable fixation without additional fastening members, and accommodates inspection jigs for automated testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connection elements are used for each battery cell, then electrical connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate connection elements into a single common connection element that electrically connects multiple battery cells simultaneously. This reduces the number of individual connection elements needed while maintaining reliable electrical connections across all cells, thereby reducing device complexity and manufacturing cost without sacrificing connection reliability.
Solution Approach 2:
The common connection element serves multiple functions by simultaneously connecting multiple battery cells, acting as a universal connector for the entire battery module. This multi-functional design eliminates the need for separate dedicated connectors for each cell, simplifying the overall structure while ensuring reliable electrical connectivity.
2Reliability
If separate connection elements are used for each battery cell, then individual cell connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
By merging multiple individual connection elements into a single common connection element that serves multiple battery cells, the patent reduces the total number of components that need to be manufactured and assembled. This consolidation lowers manufacturing costs through reduced material usage, fewer assembly steps, and simplified production processes while maintaining reliable individual cell connections.
3Quantity of substance
If battery module capacity is increased by adding more cells, then energy storage is improved, but risk of thermal propagation increases
Solution Approach 1:
The patent segments the battery module into electrically isolated groups using common connection elements that connect cells within each group but prevent electrical current flow between groups. This segmentation creates electrical isolation barriers that can contain thermal events to specific groups, reducing the risk of thermal propagation across the entire module while still allowing the module to scale in capacity.
Data Source
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AI summary
An embodiment provides a battery module including: a lower housing in which a plurality of secondary battery cells are housed; an upper housing coupled to a cover of the lower housing to cover the plurality of secondary replaceable cells; a female connector detachably installed in at least one of the lower housing and the upper housing; and a wiring harness electrically connected to the connector and the plurality of secondary battery cells. The connector may include a body provided with a plurality of terminals, a bottom surface of the body may be spaced apart from an outer surface of the at least one housing such that a space may be formed between the outer surface of the at least one housing and the bottom surface, and both side surfaces of the body may be fixed to the outer surface of the at least one housing.