Flexible Battery Terminal Connector for Positional Tolerance
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Solution Overview
Problem
Existing connection devices for battery modules in electric vehicles are not robust enough to handle positional variations of U-shaped terminals, leading to unreliable and imperfect electrical connections.
Innovation Solution
A connection device featuring a longitudinal insulation body with flexible contact blades and a connecting element that presses against the terminal's inner surface, allowing for deformation to accommodate positional deviations while maintaining a secure electrical connection, including a visual locking indicator and retaining catches for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar is screwed or soldered to the terminals, then the electrical connection is established, but the connection is not robust with respect to positional variations of terminals
Solution Approach 1:
The patent employs a flexible busbar that can deform to accommodate positional variations of terminals. The busbar includes a deformable section that bends and adjusts its shape to maintain reliable electrical contact even when terminals are misaligned due to manufacturing tolerances or relative movements, thus resolving the contradiction between connection reliability and adaptability to positional variations.
Solution Approach 2:
The connection device incorporates a deformable section in the busbar that can dynamically adjust its shape in response to positional variations of terminals. This dynamic adaptation allows the busbar to maintain optimal contact pressure and electrical connection quality despite changes in terminal positions, thereby achieving both reliability and versatility.
2Adaptability or versatility
If the busbar is deformed during mounting to accommodate positional deviations, then the positional tolerance is improved, but the installation time increases
Solution Approach 1:
The busbar is pre-formed with a deformable section during manufacturing that is designed to automatically adjust during assembly. This preliminary preparation eliminates the need for time-consuming manual deformation or adjustment during installation, as the deformable section self-adjusts to accommodate positional deviations when the connection device is assembled, thus maintaining both adaptability and efficient installation.
3Ease of manufacture
If retaining clips are used to form electrical contact, then the assembly is simple, but the device is not robust with respect to variations in position after assembly
Solution Approach 1:
The patent replaces rigid retaining clips with a flexible busbar that can deform to accommodate positional variations. The flexible busbar maintains reliable electrical contact by adapting its shape to match terminal positions, providing both assembly simplicity and robustness against positional variations without the complexity of adjustable retaining mechanisms.
4Manufacturing precision
If a rigid connection structure is used, then the manufacturing precision is high, but the adaptability to positional deviations is poor
Solution Approach 1:
The patent uses a flexible busbar with a deformable section that combines precise manufacturing features with inherent flexibility. The busbar can be manufactured with high precision for optimal contact geometry, while the deformable section allows it to adapt to positional deviations during assembly, thus achieving both manufacturing precision and adaptability.
Solution Approach 2:
The connection device incorporates a deformable section that transitions from a static rigid structure to a dynamic flexible structure during assembly. This deformable section can bend and adjust its shape to accommodate positional variations while maintaining precise electrical contact, thereby resolving the contradiction between manufacturing precision and adaptability.
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
The solution provides a durable and reliable electrical connection that tolerates positional variations, ensuring high-quality contact and easy assembly, even with U-shaped terminals, thus enhancing the robustness and reliability of the connection.
Implementation Method 1
a flexible electrical conductor disposed in the longitudinal body, the electrical conductor comprising at least one pair of flexible contact blades intended to make contact with the inner contact surface of the terminal
Implementation Method 2
at least one connecting element configured to be inserted in the connection position into the second insertion opening and between the flexible blades of the at least one pair of flexible contact blades in order to keep them pressed against the inner contact surface of the terminal
Data Source
AI summary
A device for connecting a U-shaped terminal of a battery module to an electrical conductor includes a longitudinal insulation body having at least one housing for receiving the terminal; a flexible electrical conductor disposed in the longitudinal insulation body, the electrical conductor comprising a pair of flexible contact blades configured to be arranged in the terminal and to make contact with an inner contact surface of the terminal. The device further includes at least one connecting element configured to be inserted in the connection position into the housing and between the flexible blades of the at least one pair of flexible contact blades to keep them pressed against the inner contact surface of the terminal.