Battery Terminal Connector Layout for Precise Crimping and High Current
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Solution Overview
Problem
Conventional electrical terminal connectors for battery modules are prone to installation errors, such as being installed upside down, and lack sufficient overcurrent capability for high-current applications like electric vehicles.
Innovation Solution
The proposed electrical connector features a securing plate with crimping clasps and tapered bridges made of electrically conductive material, providing stable and precise connections while accommodating high electrical currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single threaded fastener is used to secure the electrical connector to the battery terminal, then the installation process is simple, but the locational precision and stability of the electrical conductor deteriorate because the wire can easily pivot during tightening
Solution Approach 1:
The single fastener is segmented into multiple fasteners (at least two fasteners are provided). This segmentation distributes the securing function across multiple points, preventing wire pivoting while maintaining installation simplicity. Each fastener independently secures the connector at different locations, ensuring stable positioning without requiring complex single-point tightening procedures.
2Device complexity
If conventional electrical connectors are used, then the device complexity is low, but the overcurrent capability is insufficient for high-current applications such as electric vehicles
Solution Approach 1:
The connector structure incorporates local quality enhancements through tapered bridges that concentrate structural reinforcement and electrical conductivity at critical current flow paths. The bridges have varying cross-sectional areas optimized for high current carrying capacity where needed, while maintaining simpler geometry elsewhere. This allows high overcurrent capability without uniformly increasing overall device complexity.
3Ease of manufacture
If conventional flat annular connectors are used, then the manufacturing process is simple, but installation errors such as upside-down installation occur frequently
Solution Approach 1:
The connector incorporates asymmetric features including tapered bridges with specific geometric configurations and non-uniform fastener placement patterns. These asymmetric elements create a unique fit orientation that prevents upside-down installation, as the connector will only properly engage with the battery terminal in the correct orientation. The asymmetric design maintains manufacturing simplicity while ensuring reliable correct installation.
Data Source
AI summary
Electrical connectors that can be used with battery modules, such as battery modules containing one or more electrochemical cells, and that include features for precisely locating electrical conductors engaged with the electrical connectors and/or features for increasing robustness of the electrical connectors to overcurrent conditions. In some embodiments, each electrical connector includes a securing plate having multiple openings for securing the electrical connector to a positive or negative terminal of a battery module. In some embodiments, each electrical connector includes two or more tapering bridges extending between a securing plate and a pair of corresponding crimping clasps that receive corresponding respective current conductors or branches of a single current conductor during use. Electrical systems containing such electrical connectors are also disclosed.