Asymmetric Battery Module Clip for Secure Oriented Assembly

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Solution Overview

Problem

Existing bonding jumpers for assembling battery modules fail to ensure proper orientation, prevent mechanical stresses due to dimension variability, and securely maintain the connection, leading to potential electrical connection issues and module detachment.

Innovation Solution

A connecting part, or clip, with different dimensioned portions for each battery module, featuring a flexible and non-flexible branch design, snap-fit protrusion for secure attachment, and clearance for dimensional variability, ensuring proper orientation and secure assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If identical branches are used in the bonding jumper, then the assembly process is simplified, but the operator cannot be guided to properly orient the battery modules

Engineering Contradiction:

Improveassembly process simplicityVSAvoidelectrical connection safety

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies asymmetry by providing a bonding jumper with two different branches: a first branch with a first cross-sectional shape and a second branch with a second cross-sectional shape. These asymmetric shapes enable the jumper to guide proper orientation of battery modules during assembly, preventing incorrect electrical connections while maintaining manufacturing simplicity through a unified jumper structure.

Inventive Principle:

Principle #4Asymmetry

2Strength

If the bonding jumper is completely secured to both modular elements, then mechanical connection is strong, but the jumper can easily come out and cause module detachment

Engineering Contradiction:

Improvemechanical connection strengthVSAvoidconnection stability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies dynamics by designing the bonding jumper with flexible branches that can deform elastically. The jumper is inserted into cavities and secured with retaining means, but the flexible nature allows controlled movement while maintaining connection. The asymmetric cross-sectional shapes prevent complete removal, providing dynamic stability that balances strong mechanical connection with prevention of accidental detachment.

Inventive Principle:

Principle #15Dynamics

3Strength

If the bonding jumper is rigid, then structural integrity is maintained, but mechanical stresses arise due to dimension variability in modular elements

Engineering Contradiction:

Improvestructural integrityVSAvoidtolerance to dimensional variability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent applies parameter changes by making the bonding jumper flexible rather than rigid. The jumper material and structure are designed to allow elastic deformation, enabling it to adapt to dimensional variations in battery modules during assembly. This flexibility maintains structural integrity while accommodating tolerances in modular element dimensions, preventing mechanical stresses.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If clearance between modular elements is allowed, then adaptability to dimensional variability is improved, but electrical connection quality deteriorates

Engineering Contradiction:

Improvetolerance to dimensional variabilityVSAvoidelectrical connection quality

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies the intermediary principle by using the bonding jumper as a mediator between the two battery modules. The jumper's flexible branches are inserted into cavities in each module, providing a reliable electrical and mechanical connection. This intermediary structure accommodates clearance and dimensional variability while ensuring consistent electrical connection quality, as the jumper material and geometry are designed to maintain contact despite gaps between modules.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 clip effectively prevents undesirable electrical connections, securely assembles battery modules with varying dimensions, and maintains a stable connection without spontaneous disengagement, enhancing the reliability and safety of battery module assembly.

Implementation Method 1

The first branch (3a) comprises a flexible part (3a) and a non-flexible part (3b)

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250158204A1Clip for the assembly of battery modules

Publication Date: 2025.05.15 SAFT GRP SA

AI summary

A connecting part for assembling two battery modules, said connecting part including: a first portion able to be inserted into a recess of a first retaining element of a first plurality of electrochemical cells forming part of a first battery module and a second portion able to be inserted into a recess of a second retaining element of a second plurality of electrochemical cells forming part of a second battery module, the first portion and the second portion having different dimensions, such that the first portion is not suitable for being inserted into the recess of the second retaining element and/or the second portion is not suitable for being inserted into the recess of the first retaining element, a device for preventing the removal of the connecting part after its insertion into a recess of one of the two retaining elements.