Low-Profile Battery Connector with Integrated Spring Fingers
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Solution Overview
Problem
Existing battery connectors have a large profile and complex assembly, necessitating a low-profile, easy-to-assemble solution for efficient electrical connections between batteries and circuits.
Innovation Solution
A low-profile connector design featuring a dielectric body with conductive pins, resilient spring fingers, and a planar conductive plate, which includes retention fingers and a gasket for environmental sealing, allowing for secure and easy installation without tools or fasteners, and providing low impedance connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional battery connector design is used, then electrical connection is achieved, but the profile becomes large and assembly becomes complicated
Solution Approach 1:
The patent combines multiple functions into a single integrated connector assembly. The connector housing integrates the dielectric body, contact members, and retention features into one unified structure that attaches directly to the battery, eliminating the need for separate connectors and fasteners. This merging of components directly reduces assembly complexity while maintaining electrical connection functionality.
Solution Approach 2:
The connector design nests the contact members within the dielectric body, which is itself housed within the connector housing. The contact members are positioned in cavities of the dielectric body, creating a nested arrangement that reduces the overall profile while maintaining all necessary electrical connection points. This nested structure allows compact packaging of multiple functional elements.
2Ease of operation
If a traditional battery connector design is used, then electrical connection is achieved, but the profile becomes large
Solution Approach 1:
The connector design transitions from a traditional lateral attachment approach to a vertical integration approach. The connector housing attaches directly to the battery terminal in a vertical orientation, with contact members extending perpendicular to the battery surface. This dimensional reorientation reduces the horizontal profile while maintaining electrical connection capability.
Solution Approach 2:
The contact members are nested within cavities of the dielectric body, which is itself contained within the connector housing. This nested arrangement allows all functional components to be packed into a compact volume, significantly reducing the overall connector profile compared to traditional designs where components are arranged in a more spread-out configuration.
3Reliability
If the connector is designed with retention features, then the connector is securely retained, but the assembly becomes more complex
Solution Approach 1:
The retention features are merged directly into the connector housing structure. The housing includes integrated retention tabs and engagement features that work with corresponding features on the battery terminal. This integration means the retention function is built into the basic connector structure rather than requiring separate retention mechanisms, thus improving reliability without significantly increasing complexity.
Solution Approach 2:
The connector design incorporates self-aligning and self-retaining features. The retention tabs and engagement features are designed to automatically align and secure the connector to the battery terminal during installation, eliminating the need for additional fasteners or complex assembly steps. This self-service approach improves retention reliability while keeping the structure relatively simple.
4Object-affected harmful factors
If the connector provides environmental sealing, then protection against contaminants is achieved, but the manufacturing becomes more complex
Solution Approach 1:
The dielectric body serves as a flexible yet protective shell that seals the contact members within. The dielectric material forms a continuous barrier between the external environment and the internal contact components. This shell approach provides effective environmental sealing without requiring multiple separate gaskets or complex sealing mechanisms, thus protecting against contaminants while maintaining manufacturing simplicity.
Solution Approach 2:
The sealing function is merged into the dielectric body itself rather than being a separate component. The dielectric material is molded to include integrated sealing features that prevent contaminant ingress while maintaining electrical insulation. This combination of insulation and sealing functions in a single component reduces manufacturing complexity compared to designs requiring separate sealing elements.
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
The solution enables compact, versatile, and reliable electrical connections that meet environmental standards, preventing moisture intrusion and ensuring proper alignment and retention within electronic devices, while maintaining low impedance and ease of assembly.
Implementation Method 1
resilient spring fingers. Each of the resilient spring fingers is shaped to define a resilient clip configured for engaging a portion of the dielectric body
Implementation Method 2
At least one gasket is provided on the sidewall. The gasket is configured for forming a seal which prevents the intrusion of environmental contaminants around a periphery of the connector
Data Source
AI summary
A connector (200) is provided that comprises a dielectric body (DB), pins (302), and a plate (800). Each pin is captured within DB (404) so as to extend therethrough. Each pin is defined by a pair of nubs (410, 510) extending from DB's opposing faces (408, 604), respectively. Each nub is movable along an axis aligned with an elongated length of the pin. The plate is formed of a planar conductive material secured to DB adjacent to a first opposing face. The plate comprises apertures through which the pins extend in a first direction. At least one aperture is sized and shaped to form an electrical connection between the plate and selected pins. Resilient spring fingers (RSF) are formed on a periphery of the plate. Each RSF (1006) extends away from DB in a direction between a plane defined by the first opposing face and first direction of the pins.