Resilient Battery Module Connector for Stable Low-Heat Joints
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Solution Overview
Problem
Existing battery systems face issues with loose bolts causing increased connection impedance, leading to overheating and potential fires due to bolt torque attenuation in electrical connections among battery modules.
Innovation Solution
A connecting structure that uses a resilient connecting member with a bridging portion and accommodating cavity to securely hold the conducting member, eliminating the need for bolts and ensuring stable electrical connections without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolts are used to fix conducting members to battery modules, then electrical connections can be established, but the bolts are easy to loosen causing increased connection impedance and overheating
Solution Approach 1:
The patent replaces the bolt-based mechanical fastening system with a welding-based permanent joint system. The conducting member is welded directly to the battery module terminal, eliminating the bolt entirely. This substitution resolves the contradiction by providing a permanent, maintenance-free connection that cannot loosen over time, thereby improving reliability without compromising ease of operation.
Solution Approach 2:
The patent extracts and removes the bolt component from the electrical connection system. By eliminating the bolt entirely and using direct welding between the conducting member and battery module terminal, the design removes the source of the loosening problem while maintaining electrical connectivity, thus resolving the technical contradiction.
2Quantity of substance
If multiple battery modules are connected via conducting members with bolts, then energy density increases, but connection impedance increases over time due to bolt loosening
Solution Approach 1:
The welding-based connection system replaces the bolted mechanical connection, ensuring stable electrical contact that does not deteriorate over time. This allows multiple battery modules to be connected with reliable, low-impedance joints that maintain their electrical properties throughout the system's operational life.
3Ease of manufacture
If bolts are used for electrical connections, then assembly is straightforward, but heat-generation increases due to connection impedance
Solution Approach 1:
The welding process creates a permanent metallurgical bond between the conducting member and battery module terminal, providing excellent electrical contact with minimal contact resistance. This eliminates the intermittent contact and increased impedance associated with bolted connections, thereby preventing heat generation while maintaining manufacturing efficiency.
4Reliability
If resilient connecting members are used instead of bolts, then connection stability improves, but device complexity increases
Solution Approach 1:
The welding-based connection system simplifies the overall structure by eliminating the need for resilient connecting members, clamps, or other complex fastening mechanisms. The direct weld joint provides inherent stability and electrical conductivity without requiring additional components, thereby improving reliability while reducing device complexity.
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 solution provides stable electrical connections, enhances production efficiency, and prevents overheating and fires, while maintaining a high energy density and safety in battery modules.
Implementation Method 1
a resilient portion (134) of the second connecting member (13) resiliently abuts against the first connecting portion (112) and the second connecting portion (113)
Implementation Method 2
electrical connections among the battery modules are implemented via conducting members
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A connecting structure, a battery module, an energy storage apparatus, and an electronic device are provided. The connecting structure includes a connecting assembly and a conducting member. The connecting assembly includes a first connecting member and a second connecting member. The first connecting member includes a first bending portion, a first connecting portion, and a second connecting portion. The first connecting portion, the first bending portion, and the second connecting portion surround a space to define an inserting groove. The second connecting member is mounted in the inserting groove and resiliently abuts against the first connecting portion and the second connecting portion. The second connecting member includes a bridging portion, a first plate, and a second plate. Each of the first plate and the second plate is provided with a resilient portion, the resilient portion has a first sub-section.