Battery Module Connector With Vibration Buffering
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Solution Overview
Problem
Conventional connectors between battery modules in vehicle power batteries face issues such as loosening due to vibrations, leading to power interruptions and potential short circuits, and are prone to breaking under impact, affecting reliability and safety.
Innovation Solution
A connector design featuring first and second connecting pieces with a clamping unit and support, where the clamping unit comprises upper and lower plates fastened by a screw, and buffer sections with inverted U shapes to absorb vibrations and impact, enhancing connection strength and reliability, and an insulation cover to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors use metal pieces and metal foil to connect battery modules, then electrical connection is achieved, but the metal foil breaks under large impact force and the connection reliability decreases
Solution Approach 1:
The connector is divided into multiple functional components: connecting pieces for electrical connection, clamping unit for mechanical fastening, support for structural stability, and buffer section for impact absorption. This segmentation allows each component to specialize in its function, improving overall reliability and strength.
Solution Approach 2:
The buffer section with inverted U shape is designed beforehand to absorb impact forces before they can damage the electrical connection components. This preemptive cushioning protects the fragile metal foil and connecting pieces from breaking under impact.
2Reliability
If screws are used to fasten battery modules, then electrical connection is secured, but vibrations cause the screw to loosen leading to power interruption
Solution Approach 1:
The clamping unit combines multiple fastening mechanisms (clamping plates and fasteners) into a single integrated structure that simultaneously secures both battery modules. This merged structure distributes vibration forces across multiple contact points, preventing the loosening that occurs with single screw connections.
Solution Approach 2:
The buffer section is positioned beforehand to absorb vibrations before they can cause the fasteners to loosen. This preemptive vibration absorption maintains the stability of the fastening connection over time.
3Reliability
If copper wire is used for connection, then electrical conductivity is achieved, but the heavy weight creates outward tensile force on the screw causing loosening and short circuit
Solution Approach 1:
The connector separates the electrical conduction function (connecting pieces) from the mechanical support function (clamping unit and support). This segmentation allows the use of lighter-weight conductive materials without requiring heavy gauge wire, reducing the tensile force on fasteners.
Solution Approach 2:
The support structure acts as an intermediary between the battery modules and the connecting pieces. It bears the mechanical load and transmits minimal force to the electrical connection components, reducing the tensile force experienced by the conductive elements.
4Ease of manufacture
If adjacent battery modules share one connector, then assembly is simplified, but the connector must connect to terminals of both modules which decreases assembling ability
Solution Approach 1:
The connector design with first and second connecting pieces provides multi-functionality, allowing the same connector structure to adapt to different connection configurations. Each connecting piece can independently connect to different battery module terminals, maintaining versatility while enabling simplified assembly through standardized components.
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 connector design improves connection reliability and anti-impact ability, reduces the risk of short circuits, and simplifies assembly by securely fastening adjacent battery modules, ensuring stable power output and enhanced safety.
Implementation Method 1
a buffer section (213) having a substantially inverted U shape, located between the output end connecting section (211) and the clamped section (212)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A connector between battery modules and a battery system comprising the same are provided. The connector between battery modules comprises: first and second connecting pieces (21, 22), the first connecting piece (21) being electrically connected to an output end of a first battery module, the second connecting piece (22) being electrically connected to an output end of a second battery module adjacent to the first battery module, and the first connecting piece (21) and the second connecting piece (22) being electrically connected to each other so as to form an electrically-connecting part therebetween; a clamping unit configured to clamp the electrically-connecting part; and a support (5), the clamping unit being fixed onto the support (5) so as to support the electrically-connecting part between the first connecting piece (21) and the second connecting piece (22).