Flexible Strip Electrical Connector Tolerance Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors for battery modules or cells have limited ability to compensate for component spacing tolerances, leading to inefficiencies in connecting high electrical currents, particularly in electric motor vehicles.
Innovation Solution
A single-piece electrical connector design featuring a flexible, flat conductive strip with secured contact brackets that allow for adjustable spacing and clamping mechanisms, enabling robust and adaptable connections between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid electrical connector structure is used, then structural stability is improved, but the ability to compensate for spacing tolerances deteriorates
Solution Approach 1:
The patent applies the dynamics principle by making the strip flexible rather than rigid, allowing it to dynamically adapt to spacing variations between contact brackets while maintaining structural integrity. The flexible strip can bend and deform to accommodate tolerance ranges, resolving the contradiction between stability and adaptability.
Solution Approach 2:
The patent changes the physical parameter of the strip from rigid to flexible, enabling it to accommodate spacing variations. This parameter change allows the connector to adapt to different spacing conditions while maintaining electrical connectivity, thus resolving the contradiction between structural stability and tolerance compensation.
2Adaptability or versatility
If multiple separate components are used in the electrical connector, then adaptability is improved, but the risk of component loss and assembly complexity increases
Solution Approach 1:
The patent merges the strip and contact brackets into a single integrated component, eliminating the need for separate parts. This merging maintains the adaptability of the flexible strip while reducing assembly complexity and eliminating the risk of component loss during assembly.
Solution Approach 2:
The patent segments the integrated connector into functional regions (contact brackets, strip, clamping regions) that can be manufactured separately but function as a unified component, balancing manufacturing ease with assembly simplicity.
3Reliability
If the contact bracket is designed with a clamping mechanism, then the reliability of electrical connection is improved, but the manufacturing complexity increases
Solution Approach 1:
The clamping mechanism is designed to automatically engage and secure contact blades without additional fastening steps. The contact brackets self-secure the blades through their inherent elastic deformation, improving reliability while maintaining manufacturing simplicity.
Solution Approach 2:
The patent replaces complex mechanical fastening systems with a simple elastic clamping mechanism that uses the natural elasticity of the contact bracket material to secure contact blades, reducing manufacturing complexity while ensuring reliable electrical connections.
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 cost-effective, compact, and reliable method for connecting components with large tolerance compensation, ensuring secure and efficient electrical conductivity while simplifying assembly and reducing component loss risks.
Implementation Method 1
the first and/or the second contact bracket has/have a plurality of inner resilient bars and a plurality of outer resilient bars which are arranged on a common strut. In this instance, the clamping region is formed between the inner resilient bars and the outer resilient bars
Data Source
AI summary
An electrical connector comprises a first single-piece contact bracket, a second single-piece contact bracket and a flat, flexible, electrically conductive strip. The first contact bracket and the second contact bracket are secured to the strip with spacing.