Battery Pack Socket Terminals for Tool-Free Module Assembly
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Solution Overview
Problem
Existing battery packs face difficulties in easily connecting and disconnecting electrode terminals of battery modules, making assembly, disassembly, and maintenance challenging due to the complexity of nut-based fastening systems.
Innovation Solution
A battery pack design featuring socket terminals with elastic contactors, flexible bus bars, and a sub-pack case with hinge-coupled covers that allows for press-fitting of electrode terminals, enabling easy electrical connection and attachment/detachment of battery modules without the need for separate tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nut-based fastening system is used to connect electrode terminals, then electrical connection is achieved, but assembly and disassembly become difficult and time-consuming
Solution Approach 1:
The patent replaces the traditional nut-based mechanical fastening system with a spring-based elastic contact system. The spring terminals provide reliable electrical connection through elastic force rather than threaded fastening, enabling tool-free assembly and disassembly while maintaining connection reliability. This substitution of mechanical systems resolves the contradiction between connection reliability and operational ease.
Solution Approach 2:
The spring terminals automatically maintain electrical connection through their inherent elastic properties. The elastic contacts self-adjust to maintain optimal contact pressure with the electrode terminals, providing self-regulating connection without requiring external fastening operations. This self-service mechanism eliminates the need for nuts and bolts while ensuring reliable electrical connection.
2Stability of the object's composition
If traditional fastening methods are used for battery module assembly, then structural stability is achieved, but maintenance and reassembly become complex
Solution Approach 1:
The patent divides the battery pack into modular components (battery modules, spring terminals, springless terminals) that can be independently assembled and disassembled. Each module maintains structural stability through its own internal configuration while allowing easy separation from other modules. This segmentation enables maintenance of individual modules without affecting the entire battery pack structure.
Solution Approach 2:
The spring terminals provide dynamic connection capability, allowing the battery modules to be easily inserted and removed while maintaining stable electrical connection during operation. The elastic springs absorb mechanical stresses and maintain consistent contact pressure, providing both structural stability and ease of maintenance through reversible assembly operations.
3Reliability
If multiple separate fastening components are used, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the functions of electrical connection and mechanical fastening into a single spring terminal component. The spring terminal simultaneously provides electrical conductivity and mechanical retention through its integrated spring structure, eliminating the need for separate nuts, bolts, and washers. This merging of functions reduces device complexity while maintaining connection reliability.
Solution Approach 2:
The spring terminals serve multiple functions: electrical conduction, mechanical fastening, stress absorption, and position maintenance. This multi-functionality eliminates the need for multiple specialized components, simplifying the overall device structure while ensuring reliable electrical connection and stable mechanical attachment of battery modules.
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
Facilitates easy electrical connection of battery modules, reduces assembly and disassembly time, and prevents quality issues like loose connections and contact defects, while allowing for efficient series connection and easy maintenance.
Implementation Method 1
a plurality of elastic contactors extendedly formed at one side of a cylindrical body
Data Source
AI summary
Provided is a battery pack having easily attachable and detachable battery modules, in which a plurality of battery modules are inserted, respectively, into receiving parts formed in a sub pack case, such that electrode terminals of the battery modules are coupled to a terminal stand formed at one side of the sub pack case to thereby be electrically connected to each other, and a sub pack case cover formed at the other side of the sub pack case is closed to fix the battery modules.