Battery Module Conductive Elastic Connection for Tolerance Absorption
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Solution Overview
Problem
Existing battery designs fail to efficiently integrate individual battery cells into packs without modular configurations, leading to complex assembly processes and increased costs due to additional components required for electrical connections.
Innovation Solution
A battery structure and module incorporating a conductive elastic member to facilitate electrical contact between two battery modules, utilizing stacked conductive plates and elastic members to achieve electrical connection, thereby simplifying assembly and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components are used to achieve electrical connection between battery modules, then electrical connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The conductive elastic member integrates both electrical conductivity and elastic deformation capabilities into a single component. This component simultaneously provides electrical connection and absorbs assembly tolerances, eliminating the need for separate rigid conductors and tolerance compensation mechanisms. The merging of functions reduces device complexity while maintaining connection reliability.
Solution Approach 2:
The conductive elastic member utilizes material parameter changes through elastic deformation to adapt to assembly tolerances. The material's elastic properties allow it to deform and accommodate dimensional variations between battery modules while maintaining continuous electrical contact, thus ensuring reliable connection without complex assembly procedures.
2Reliability
If additional components are used to achieve electrical connection, then electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
By combining electrical conductivity and elastic tolerance absorption into a single conductive elastic member, the number of components is reduced. This simplifies the manufacturing process, reduces component procurement costs, and lowers assembly complexity, thereby decreasing overall manufacturing cost while ensuring reliable electrical connection.
Solution Approach 2:
The conductive elastic member automatically adjusts its deformation state based on the assembly tolerance encountered during manufacturing. It self-regulates the electrical connection quality without requiring external adjustment mechanisms or complex quality control procedures, simplifying manufacturing and reducing costs.
3Reliability
If additional components are used for electrical connection, then connection stability is improved, but assembly time increases
Solution Approach 1:
The integration of electrical conduction and elastic tolerance compensation into one component reduces the number of assembly steps. The conductive elastic member can be installed in a single operation that simultaneously establishes electrical connection and accommodates tolerance variations, significantly reducing assembly time compared to multi-component solutions.
Solution Approach 2:
The elastic member's ability to dynamically adjust its deformation parameter during assembly allows for quick adaptation to tolerance variations without requiring precise pre-adjustment or multiple adjustment steps. This rapid self-adjustment capability reduces assembly time while ensuring stable connection.
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 proposed solution effectively addresses integration and assembly challenges by eliminating the need for additional components, simplifying the assembly process, and reducing costs while ensuring reliable electrical connections between battery modules.
Implementation Method 1
absorbing assembly tolerance through elastic deformation
Data Source
Figure 1
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Figure 3
AI summary
A battery structure (1) includes two battery modules (10a, 10b) and a conductive elastic member (112). Each of the two battery modules (10a, 10b) includes a housing (100), a plurality of battery cells (102), a first holder (104), a second holder (106), a first conductive plate (108) and a second conductive plate (110). The battery cells (102) are disposed in the housing (100). The first holder (104) and the second holder (106) accommodate the battery cells (102). The first conductive plate (108) is disposed on the first holder (104) and connected to the battery cells (102). The second conductive plate (110) is disposed on the second holder (106) and connected to the battery cells (102). The conductive elastic member (112) is disposed between and in contact with the first conductive plate (108) and the second conductive plate (110) of the two battery modules (10a, 10b).