Battery Connector Module With Stepped Locking for Compact Stability
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Solution Overview
Problem
Existing battery modules face challenges with space utilization due to the need for miniaturization and integration, as well as issues with mechanical stability and connection reliability, particularly in environments with vibration and impact.
Innovation Solution
A connector module design featuring a first and second connector with a coupling housing that includes a stepped structure to secure electrical connections and prevent separation, utilizing a coupling body with a stepped portion and a ring structure for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the capacity of the batteries and the number of batteries mounted on the battery pack/battery module increase, then the energy density increases, but the inner space of the battery pack/battery module becomes very narrow
Solution Approach 1:
The second connector is inserted into the first connector, forming a nested structure where one connector housing is placed inside another. This nesting arrangement reduces the overall space required for connection components, allowing more batteries to be mounted within the limited inner space of the battery module while maintaining effective electrical connections.
2Reliability
If internal components of the battery pack/battery module are coupled by soldering, then electrical connection is achieved, but cracks occur or deterioration in manufacturing yield
Solution Approach 1:
The patent replaces the soldering process with a mechanical coupling system consisting of connector housings, conductive parts, and coupling structures. This mechanical connection method eliminates the thermal and chemical processes of soldering, preventing crack formation and improving manufacturing yield while maintaining reliable electrical connection between battery terminals.
3Volume of stationary object
If the internal components of the battery pack/battery module are miniaturized, then space utilization improves, but damage due to mechanical vibration/impact or connection failure occurs
Solution Approach 1:
The connector assembly combines multiple materials with complementary properties: conductive parts for electrical connection, housing materials for structural support and protection, and coupling structures for mechanical stability. This composite construction provides both miniaturization and enhanced resistance to mechanical vibration and impact, preventing connection failure while maintaining compact dimensions.
4Volume of moving object
If a connector module with reduced height is designed, then the overall volume is reduced, but the coupling force between components may be insufficient
Solution Approach 1:
The patent compensates for reduced height in the vertical dimension by enhancing the coupling mechanism in horizontal and depth dimensions. The coupling housing and coupling structures extend laterally and provide multi-point contact, distributing and increasing the total coupling force despite the reduced overall height of the connector module.
Data Source
AI summary
A connector module according to an embodiment of the present invention may include a first connector including a first connector housing and a first conductive part coupled to the first connector housing, and a second connector coupled to the first connector. The second connector may include a second connector housing including a frame inserted into and coupled to the first connector and a connection part connected to one surface of the frame and coupled to the first connector, a second conductive part of which at least a portion is inserted into and coupled to the frame so as to be electrically connected to the first conductive part, and a coupling housing configured to surround the second connector housing so as to couple the second connector housing to the second conductive part and restrict separation of the connection part from the frame through a stepped structure.