Interlocking Electrode Connector for Battery Module

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Solution Overview

Problem

Existing battery pack manufacturing methods face challenges in achieving stable electrical connections between batteries, which are crucial for realizing sufficient output power and capacity, especially for larger devices that require multiple batteries.

Innovation Solution

The use of an electrode connector with sequentially aligned lead plates featuring protrusions and recesses for secure alignment and connection, along with an insulating connection unit, ensures rigid and stable electrical connections between batteries, allowing for efficient welding or soldering of electrode terminals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If batteries are electrically connected using conventional methods, then electrical connection can be established, but the connection stability and rigidity are insufficient

Engineering Contradiction:

Improveconnection stabilityVSAvoidconnection rigidity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The lead plates are nested together through protrusions and recesses, where the protrusion of one lead plate fits into the recess of the adjacent lead plate, creating a interlocked structure that enhances both connection stability and rigidity while maintaining electrical connectivity

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The electrode connector is segmented into multiple lead plates with protrusions and recesses at different positions, allowing each segment to contribute to the overall structural rigidity and connection stability through their interlocking arrangement

Inventive Principle:

Principle #1Segmentation

2Reliability

If lead plates are closely aligned for electrical connection, then electrical conductivity is improved, but structural rigidity decreases

Engineering Contradiction:

Improveelectrical connectionVSAvoidstructural rigidity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The protrusions and recesses create a nested interlocking structure between lead plates that are spaced apart, maintaining electrical conductivity through the nested connection while the spaced-apart arrangement with interlocking features enhances structural rigidity

Inventive Principle:

Principle #7Nested doll (Nesting)

3Power

If multiple batteries are connected in series/parallel, then output power and capacity increase, but manufacturing complexity increases

Engineering Contradiction:

Improveoutput power and capacityVSAvoidmanufacturing complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The electrode connector with standardized protrusions and recesses serves as a universal connection structure that can accommodate multiple batteries in series or parallel configurations, simplifying the manufacturing process by providing a repeatable, multi-functional connection solution

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The protrusions and recesses are pre-formed on the lead plates during manufacturing, enabling rapid assembly of multiple batteries without requiring complex alignment procedures, thus reducing manufacturing complexity while supporting high power and capacity configurations

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS8703324B2Electrode connector and battery module using the same

Publication Date: 2014.04.22 SAMSUNG SDI CO LTD

AI summary

An electrode connector and a battery module using the same are provided. The electrode connector includes a plurality of lead plates sequentially aligned and for electrically connecting a plurality of batteries, and a connection unit for integrally connecting the lead plates. Each of the lead plates includes a protrusion and a recess. The protrusion of one lead plate is accommodated in the recess of another lead plate. The one lead plate and the another lead plate are spaced apart from each other.