Battery Pack Connector Structure to Prevent Plug Module Misinstallation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors for battery packs are prone to incorrect installation of different types of plug modules, leading to installation failures.
Innovation Solution
A connector design with integrally formed female and male barrels on separate plug cores, allowing for simplified installation by connecting the plug cores to the respective devices, eliminating the need for separate module installation and reducing the likelihood of errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate plug modules are used for different functions, then the connector can support multiple functions (power and signal transmission), but the installation complexity increases and errors in modular installation occur
Solution Approach 1:
The patent combines multiple plug modules (power module with male/female barrels and signal module with pins) into a single integrated plug core structure. The housing integrates receiving cavities for both power terminals and signal terminals, allowing simultaneous installation and connection of multiple functions through one unified component rather than separate modular assemblies.
2Ease of manufacture
If separate plug modules are used, then the connector can be designed with modular architecture, but the likelihood of installation errors increases
Solution Approach 1:
The patent pre-arranges the internal structure of the plug core with dedicated receiving cavities and positioning features for both power and signal terminals during manufacturing. The housing is pre-formed with integrated cavities that guide and constrain the installation of terminals, ensuring correct positioning and reducing the likelihood of installation errors by having the structural framework prepared in advance.
3Device complexity
If completely identical openings are provided for both plug cores, then the connector structure is simple and symmetric, but the risk of reverse installation occurs
Solution Approach 1:
The patent employs asymmetric design elements in the plug core structure, including non-symmetric arrangement of terminals within the housing, asymmetric positioning of mounting features, and differentiated opening configurations between the first and second plug cores. This asymmetry creates mechanical compatibility only in the correct orientation, preventing reverse installation while maintaining reasonable structural simplicity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A connector including a first plug core (1) and a second plug core (2). The first plug core is configured to connect to a first device. The first plug core includes a first body (11) and a female barrel (12) integrally formed with the first body. The second plug core is configured to connect to a second device. The second plug core includes a second body (21) and a male barrel (22) integrally formed with the second body. The female barrel is plugged and matched with the male barrel to conduct the first device and the second device. When the connector is installed, the problem caused by the incorrect installation of the plug module does not need to be considered, the connection and installation process of the battery pack is effectively simplified, the installation complexity is reduced, and the likelihood of connector installation errors is reduced. As such, the connector can effectively realize the smooth installation and connection of the battery pack.