Battery Connector Module With Recessed Locking for Low-Profile Assembly

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Solution Overview

Problem

Existing battery modules face challenges in reducing overall volume, ensuring easy mounting and detachment in limited spaces, preventing damage from mechanical vibration and impact, and maintaining structural stability due to issues with soldering and miniaturization.

Innovation Solution

A connector module with a reduced height is designed, featuring a first connector with a recessed portion and a conductive part, and a second connector with a conductive part and a coupling housing to lock the components, enhancing coupling force and structural stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the connector module height is reduced to minimize space occupation, then the overall volume of the battery module is reduced, but the coupling force between components may be compromised

Engineering Contradiction:

Improveoverall volume of battery moduleVSAvoidcoupling force between components

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The second connector housing is inserted into the first recessed portion, creating a nested structure that reduces overall height while maintaining connection integrity. The coupling housing further nests around the second connector housing and conductive part, providing locking functionality within the minimized space envelope.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent transitions from vertical stacking to horizontal insertion by having the second connector housing insert into the first recessed portion laterally. This dimensional change allows for reduced height occupation while maintaining adequate coupling force through the insertion and locking mechanism.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If internal components are miniaturized to increase energy density, then the battery capacity per volume increases, but damage due to mechanical vibration and impact becomes more likely

Engineering Contradiction:

Improvebattery capacity densityVSAvoiddamage from mechanical vibration and impact

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The coupling housing provides a protective enclosure around the second connector housing and conductive part before mechanical stress occurs. This pre-protective structure cushions against vibrations and impacts that could damage the miniaturized internal components.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The recessed portion and coupling housing create curved, accommodating geometries that better distribute mechanical stresses from vibration and impact, protecting the miniaturized components from concentrated stress points that would cause damage.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If traditional soldering is used to couple internal components, then electrical connections are established, but cracks occur and manufacturing yield deteriorates

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing yield

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the thermal soldering process with a mechanical insertion and locking system. The second connector housing inserts into the first recessed portion and is secured by the coupling housing, eliminating the need for soldering while maintaining reliable electrical connections through direct mechanical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If the connector module is designed for easy mounting and detachment in limited space, then assembly convenience is improved, but structural stability may be compromised

Engineering Contradiction:

Improvemounting and detaching convenienceVSAvoidstructural stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The connector module is segmented into distinct components: the first connector with recessed portion, the second connector with housing and conductive part, and the separate coupling housing. This segmentation allows for easy sequential assembly and disassembly while each component maintains its structural integrity for stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coupling housing provides a dynamic locking mechanism that secures the second connector housing to the first connector during operation, ensuring structural stability. When needed, the coupling can be easily released for detachment, providing both stability during use and ease of operation when required.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20250118915A1Connector module and battery module including the same

Publication Date: 2025.04.10 LG ENERGY SOLUTION LTD

AI summary

A connector module according to an embodiment of the present invention includes a first connector including a first connector housing that is recessed therein to define a first recessed portion and a first conductive part coupled to the first connector housing, and a second connector coupled to the first connector, wherein the second connector may include a second connector housing of which at least a portion is inserted into and coupled to the first recessed portion, a second conductive part inserted into and coupled to the second connector housing so as to be electrically connected to the first conductive part, and a coupling housing configured to pass through the second connector housing and the second conductive part so as to couple the second connector housing to the second conductive part.