Modular Battery Connector Assembly With U-Clip Cam Lock
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery connector systems are not modular, requiring redesigns to accommodate different power outputs and configurations, especially in electric vehicles, and lack a lightweight solution for connecting multiple batteries without significant weight addition.
Innovation Solution
A battery connector assembly featuring interface members, an electrical contact member with a resilient U-shaped clip, and a cam lever lock mechanism for secure and efficient electrical coupling of multiple batteries, allowing for various configurations without redesigning the entire system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional battery connector systems are used to connect multiple batteries, then electrical coupling is achieved, but the system lacks modularity and requires redesign for different power outputs and configurations
Solution Approach 1:
The connector assembly is divided into separate modular components: a connector body, an electrical contact member, and interface members that can be independently attached to batteries. This segmentation allows the same connector body to work with different battery configurations without redesigning the entire system.
Solution Approach 2:
The connector body is designed as a universal component that can accommodate different battery types and configurations through interchangeable interface members. The electrical contact member can be configured in different arrangements (series, parallel, or combinations) within the same connector body, providing multi-functionality without requiring multiple dedicated connectors.
2Reliability
If traditional battery connection methods are used, then electrical coupling is achieved, but significant weight is added to the system
Solution Approach 1:
The electrical contact member utilizes a resilient U-shaped clip structure that provides reliable electrical coupling through elastic deformation rather than rigid mechanical connection. This flexible design reduces material usage and weight while maintaining sufficient contact pressure and electrical conductivity.
Solution Approach 2:
The design replaces heavy rigid mechanical fastening systems with a resilient elastic clip mechanism that achieves secure electrical coupling through spring force. This substitution eliminates the need for additional bolts, nuts, or heavy mounting structures, significantly reducing the overall connector weight.
3Weight of stationary object
If resilient U-shaped clip is used for electrical contact, then lightweight connection is achieved, but secure retention must be ensured
Solution Approach 1:
The U-shaped clip is designed with controlled elastic deformation characteristics that allow it to dynamically adapt to the interface members it connects. The clip's resilience provides continuous contact force that compensates for manufacturing tolerances and thermal expansion, ensuring secure retention while maintaining lightweight construction.
Solution Approach 2:
The U-shaped clip's curved geometry provides natural stress distribution and enhanced engagement with the interface members. The arc shape allows the clip to conform to the battery terminals and distribute contact forces evenly, improving retention reliability without requiring additional weight or complex structures.
4Reliability
If cam lever lock mechanism is added for secure coupling, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The cam lever lock mechanism is integrated into the connector body as a unified structure rather than a separate assembly. The cam lever, lock surfaces, and release mechanism are combined with the electrical contact member and housing, reducing the number of discrete parts while providing secure locking functionality.
Solution Approach 2:
The cam lever lock mechanism is designed to be operated by the user through a simple lever motion that automatically engages the locking surfaces and secures the interface members. The mechanism provides visual or tactile feedback when locked, allowing users to self-verify proper connection without requiring additional tools or complex procedures.
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
Enables modular and lightweight connection of multiple batteries, providing flexible power outputs without increasing system weight, ensuring reliable and efficient electrical coupling through the use of a resilient U-shaped clip and cam lever lock mechanism.
Implementation Method 1
the electrical contact member comprises a fold conjoining the upper contact plate and the lower contact plate so as to form a resiliently biased U-shaped clip
Data Source
AI summary
A battery connector assembly for mechanically and electrically coupling two or more batteries, includes: at least two interface members, each interface member configured to connect to respective terminals of two adjacent batteries; an electrical contact member, configured to operably attach to the at least two interface members so as to provide an electrically conductive conduit between the two adjacent batteries; and a connector housing, with a slot adapted to retainingly receive and cooperate with the electrical contact member.