Clip Terminal Connector Structure for Repeated Battery Pack Mating
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Solution Overview
Problem
Connectors used in battery management systems suffer from permanent deformation and connection failures due to repeated insertion and removal, leading to reliability issues in battery packs.
Innovation Solution
A connector design featuring elastically deformable clip terminal units and a terminal housing with extension structures and locking protrusions that distribute and offset insertion forces, providing support and heat dissipation, thereby reducing deformation and improving connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector is repeatedly connected and disconnected, then the connection and disconnection operations are performed, but the connection region becomes damaged or permanently deformed leading to connection failure
Solution Approach 1:
The patent applies beforehand cushioning by designing the connection region with increased thickness and adding support portions that extend from the terminal housing to support the clip terminal units. This structural reinforcement is built in advance to withstand the repeated mechanical stresses of connection and disconnection operations, preventing permanent deformation and maintaining connection reliability over time
2Reliability
If the connection region thickness is increased to prevent deformation, then durability is improved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the connector into distinct functional regions: the connection region with increased thickness for durability, the clip terminal units for electrical connection, and the support portions extending from the terminal housing. This segmentation allows each part to perform its specific function optimally while maintaining overall structural integrity without excessive complexity
Solution Approach 2:
The patent applies local quality by selectively increasing the thickness only in the connection region where mechanical stress occurs during connection and disconnection, rather than uniformly thickening the entire connector. The support portions are strategically positioned to provide reinforcement exactly where needed, maintaining durability while minimizing overall device complexity
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 connector design effectively reduces permanent deformation and connection failures, enhancing the durability and heat dissipation performance of the connector, ensuring reliable operation even with frequent insertions and removals.
Implementation Method 1
a first clip terminal unit and a second clip terminal unit configured to be elastically deformable and to contact a counterpart connection terminal
Implementation Method 2
a support portion extending from the connection portion and configured to be supported by the sidewall of the terminal housing
Implementation Method 3
a terminal housing including a side wall configured to electrically insulate the first clip terminal unit and the second clip terminal unit from an outside
Data Source
AI summary
A connector with increased durability is provided. A connector includes a mount electrically connected to a battery management unit configured to manage voltages of a plurality of battery cells; a first clip terminal and a second clip terminal configured to be elastically deformable and configure to contact a counterpart connection terminal; and a terminal housing including a side wall configured to electrically insulate the first clip terminal and the second clip terminal from an outside, wherein each of the first clip terminal and the second clip terminal includes a connection portion having a part configured to contact the counterpart connection terminal inserted between the first clip terminal and the second clip terminal; and a support portion extending from the connection portion and configured to be supported by the sidewall of the terminal housing.