Battery Pack Connection Assembly Using Intersecting Conductor Insertion

The patent introduces a third conductor as an intermediary component that facilitates the connection between the first conductor (power supply-side terminal) and the second conductor (power reception-side terminal). This third conductor acts as a mediator that guides and aligns the connection process, preventing direct misalignment between the first and second conductors. The intermediary structure includes alignment features and guiding mechanisms that ensure proper positioning during assembly, thereby improving assemblability while maintaining connection reliability.

The patent utilizes a spatial arrangement where the third conductor is inserted from a direction intersecting the first direction (the direction between first and second conductors). This dimensional approach allows the third conductor to approach the connection interface from a different angle, enabling alignment and connection establishment without requiring precise direct alignment between the first and second conductors. This dimensional change transforms the assembly process from a single-direction alignment problem to a multi-directional insertion process.

The third conductor serves as a precision alignment mediator that incorporates built-in alignment features such as guide rails, positioning pins, or tapered surfaces. These features mechanically guide the first and second conductors into precise alignment during the connection process, eliminating the need for high-precision manual alignment. The intermediary structure absorbs and compensates for dimensional tolerances, ensuring consistent alignment precision across multiple assemblies.

The third conductor is pre-configured with alignment features and positioning structures before the connection process. This preliminary preparation of the intermediary component ensures that when the connection is made, the alignment is already established by the pre-formed geometric constraints of the third conductor, rather than requiring precise alignment to be achieved during the actual connection act.

The third conductor is designed to perform multiple functions simultaneously: it serves as an electrical conductor, an alignment guide, a positioning element, and a mechanical connector. By integrating these multiple functions into a single component, the patent avoids the need for separate alignment fixtures, positioning devices, and connection elements. This multi-functionality reduces the overall number of components and simplifies the assembly process despite the intersecting insertion direction.

The patent merges the alignment function, connection function, and electrical conduction function into a single integrated third conductor structure. Rather than using separate components for alignment and connection, the third conductor combines these functions, reducing the total component count and simplifying the overall connection structure while maintaining improved assemblability through the intersecting insertion approach.