Battery Pack Connector Pad Layout for Higher Shear Strength
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Solution Overview
Problem
Existing battery pack connectors are prone to breakage and damage during assembly and disassembly due to their thin thickness and plating, which affects their shear strength and tensile strength.
Innovation Solution
The connector design includes first and second pads arranged at opposing ends, with third and fourth pads symmetrically positioned inside the first and second pads, respectively. These pads are arranged in a rectangular shape to form boundary lines with open portions, enhancing the connector's rigidity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the connector uses thin thickness and plating to reduce weight and material usage, then weight and material consumption are reduced, but shear strength and tensile strength deteriorate, causing breakage during assembly and disassembly
Solution Approach 1:
The connector is divided into multiple pad structures (first pads, second pads, third pads, fourth pads) with different functions and positions. The first and second pads provide primary electrical connection, while the third and fourth pads provide additional structural support and reinforcement, distributing mechanical stresses across multiple segments rather than relying on a single thick structure
Solution Approach 2:
The connector employs composite construction by combining multiple pad layers (first, second, third, and fourth pads) with different geometric configurations. This multi-layer composite structure provides both the electrical conductivity needed for thin plating and the mechanical strength required for assembly operations, achieving a balance between weight reduction and strength requirements
2Loss of substance
If the connector uses thin thickness to reduce material usage and cost, then material consumption is reduced, but reliability deteriorates due to increased breakage risk during attachment and detachment
Solution Approach 1:
The connector structure is segmented into four distinct pad groups positioned at different locations. This segmentation allows the thin-plated first and second pads to perform electrical connection functions while the third and fourth pads provide distributed mechanical reinforcement, reducing the probability of complete connector failure during assembly operations
Solution Approach 2:
The third and fourth pads are positioned in advance to provide structural cushioning and support during the assembly and disassembly processes. These additional pads act as preemptive reinforcement elements that absorb mechanical stresses before they can propagate to critical failure points in the thin-plated connector structure
Data Source
AI summary
A connector of a battery pack includes first pads at both sides of one end of the connector, and second pads at both sides of another end of the connector, wherein the first pads are in contact with each of first and second open portions, and the second pads are in contact with each of third and fourth open portions.