Low-Profile Battery Connector With U-Shaped Lateral Wings
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Solution Overview
Problem
Existing connection elements for batteries limit the compactness and energy density of interconnected battery sets due to their spatial requirements above the terminals.
Innovation Solution
A connection element with a metal body featuring a first wing, a central U- or V-shaped part, and a second wing, designed to be welded onto the lateral surfaces of the terminals, allowing for a more compact and energy-dense assembly by minimizing the prominence above the terminals and providing electrical and mechanical connection without occupying additional space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional busbar connection elements are used, then electrical connection between terminals is achieved, but the connection elements occupy significant space above the terminals, limiting compactness and energy density
Solution Approach 1:
The connection element transitions from a traditional vertical busbar configuration to a planar wing structure that connects terminals laterally along their surfaces. This dimensional change allows the connection to be made within the plane of the terminal surfaces rather than extending vertically above them, significantly reducing the space occupied while maintaining electrical connection reliability through increased contact area.
Solution Approach 2:
The connection element is divided into multiple wings (first wing and second wing) that can be independently positioned and welded to different terminals. This segmentation allows each wing to make optimal contact with its respective terminal surface, ensuring reliable electrical connection while the overall distributed structure occupies less vertical space compared to a single vertical busbar.
2Ease of manufacture
If connection elements extend above terminals, then welding and electrical connection are facilitated, but the prominence in thickness direction increases, reducing energy density
Solution Approach 1:
Instead of extending vertically above terminals to facilitate welding, the connection element uses lateral wings that extend along the terminal surfaces in the plane direction. This dimensional shift provides adequate welding surface area and accessibility while keeping the thickness direction dimension minimal, thus facilitating manufacturing without increasing prominence.
Solution Approach 2:
The connection element merges the functions of electrical connection, mechanical support, and welding interface into a single planar wing structure that lies flush with the terminal surfaces. This integration eliminates the need for separate vertical extension components, achieving welding accessibility through the wing's lateral extent rather than vertical prominence.
3Volume of moving object
If compact connection elements are used, then energy density increases, but adaptability to terminal variations and thermal expansion may be reduced
Solution Approach 1:
The connection element incorporates flexible or elastically deformable portions in its structure, allowing it to dynamically adapt to variations in terminal dimensions, positions, and thermal expansion. This dynamic capability enables the compact connection element to maintain reliable electrical connection and mechanical attachment despite changes in terminal geometry or thermal conditions, without requiring additional space.
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 enables a more compact and energy-dense battery assembly by providing an effective electrical connection between terminals without increasing the thickness direction space, allowing for better energy delivery within the same volume and accommodating thermal expansion and potential swelling of the batteries.
Implementation Method 1
a connection element for connecting electrically, and mechanically, along a direction of connection, a lateral surface of a first terminal of a first accumulator to a lateral surface of a second terminal of a second accumulator
Implementation Method 2
a first wing suitable for being welded onto the lateral surface of the first terminal, a central part, and a second wing suitable for being welded onto the lateral surface of the second terminal
Data Source
AI summary
A connection element for electrically, and mechanically connecting in a direction of connection, a first terminal of a first accumulator to a second terminal of a second accumulator, the first terminal and the second terminal protruding in a thickness direction, the connection element comprising a metal body having a first wing suitable for being welded onto the first terminal, a central part, and a second wing suitable for being welded onto the second terminal, the central part having a U-shape or a V-shape, the first wing and the second wing extending along the legs of the “U” or the “V”, respectively, the connection element being less prominent than, or at the same level in the thickness direction as at least one of the first terminal and of the second terminal.