Battery Pack Connector Multi-Layer Pad Alignment
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Solution Overview
Problem
Existing battery pack connectors lack sufficient rigidity and tensile/shear strength, leading to potential damage or detachment during attachment/detachment, due to the formation of step-differences between stacked layers caused by external impacts.
Innovation Solution
A battery pack connector design featuring multiple layers with pad portions arranged at corresponding positions, allowing vertical overlap and spacing to enhance rigidity and prevent step-differences, thereby improving tensile and shear strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers are stacked to increase connector strength, then tensile and shear strength improve, but step-differences form between layers causing reduced rigidity
Solution Approach 1:
The patent transitions from a single-layer planar structure to a multi-layer stacked structure, adding the vertical dimension (height) to the connector design. This dimensional change allows the connector to gain tensile and shear strength through layer stacking while maintaining rigidity through precise alignment of pad portions across layers, effectively resolving the contradiction between strength improvement and rigidity maintenance.
Solution Approach 2:
The patent implements a nested structure where multiple connector layers are stacked and interlocked through vertically overlapping pad portions. Each layer is positioned within the overall connector assembly, with pads from different layers nesting over one another in the vertical direction. This nesting approach allows strength accumulation through stacking while preventing step-differences that would compromise rigidity.
2Strength
If multiple layers are stacked to increase connector strength, then shear strength improves, but step-differences form between layers causing potential damage
Solution Approach 1:
The patent utilizes the vertical dimension by stacking multiple layers to enhance shear strength. The layered configuration distributes shear forces across multiple interfaces, increasing overall shear resistance. Simultaneously, the vertical overlap of pad portions eliminates step-differences that would create stress concentration points, thereby improving damage resistance and reliability.
Solution Approach 2:
The patent employs a design where pad portions overlap vertically in advance, creating a cushioning effect that prevents step-differences from forming under external impacts. This pre-positioned overlapping structure acts as a buffer that absorbs and distributes mechanical stresses before they can cause damage, thereby enhancing reliability and damage resistance.
3Stability of the object's composition
If pad portions are arranged to overlap vertically, then rigidity increases, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements a nested pad arrangement where pad portions from different layers are positioned to overlap vertically. This nesting configuration inherently guides alignment during manufacturing, as each pad is positioned relative to pads in adjacent layers. The overlapping design provides natural registration features that reduce the complexity of achieving precise alignment, thereby managing manufacturing precision requirements while maintaining rigidity.
Data Source
AI summary
A battery pack connector may include a plurality of layers stacked on top of each other along a vertical direction, and a plurality of pad portions arranged at corresponding positions in respective ones of the plurality of layers in central portions of the respective layers.