Battery Connector Module With Interlocking Mount for Vibration Resistance

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery pack and module structures face challenges in effectively connecting internal components due to limited space, mechanical vibration, and impact, leading to potential damage and connection failures.

Innovation Solution

A connector module with a first connector featuring a protrusion and a second connector with a combtooth structure, allowing easy mounting and detachment, and incorporating a coupling mechanism to prevent damage from mechanical vibration and impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering method is used to couple internal components, then electrical connection is achieved, but cracks occur and manufacturing yield deteriorates

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing yield

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the soldering process with a mechanical insertion system where connectors are simply inserted into connector holes and fixed with insertion fixing structures. This eliminates the need for thermal soldering processes, preventing cracks while maintaining electrical connection reliability and improving manufacturing yield.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent divides the connection system into separate male and female connector components that can be independently manufactured and assembled. The first connector with protrusions fits into the second connector with recesses, creating a modular assembly that improves manufacturing efficiency and reduces defects compared to monolithic soldered connections.

Inventive Principle:

Principle #1Segmentation

2Quantity of substance

If internal components are miniaturized, then energy density increases, but damage due to mechanical vibration and impact occurs

Engineering Contradiction:

Improveenergy densityVSAvoidresistance to mechanical damage

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent incorporates insertion fixing structures that pre-establish mechanical interlocking before vibration or impact occurs. The protrusions and recesses create a secure fit that cushions against mechanical stresses, preventing damage to miniaturized components while maintaining high energy density.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent uses nested connector structures where the first connector is inserted into the second connector, creating a layered, space-efficient assembly. This nested design allows miniaturization while maintaining structural integrity through interlocking geometries that resist vibration and impact.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of operation

If connector structure is simplified for easy mounting, then assembly ease improves, but connection stability may deteriorate

Engineering Contradiction:

Improvemounting easeVSAvoidconnection stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent employs asymmetric connector geometries where the first connector has specific protrusion shapes that correspond to matching recesses in the second connector. This asymmetric design enables easy directional insertion while preventing incorrect assembly and ensuring stable, reliable connections through precise geometric matching.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS20260024826A1Connector Module

Publication Date: 2026.01.22 LG ENERGY SOLUTION LTD

AI summary

A connector module according to an embodiment of the present invention includes a first connector provided with a first conductive part, and a second connector inserted into and mounted on the first connector and provided with a second conductive part electrically connected to the first conductive part, wherein the first connector may include a protrusion protruding from the inner bottom surface, with the first conductor mounted thereon.