Modular Electrical Connector with Retainer for Battery Systems
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Solution Overview
Problem
Existing electrical connection assemblies for battery cells in electric vehicles face challenges in reducing manufacturing costs and ensuring stable, long-term connections, particularly due to complex assembly requirements and potential electrochemical corrosion between different metal connectors.
Innovation Solution
A modularized electrical connector system comprising a first and second connector made of different metal materials, connected via welding, with a retainer for enhanced stability and corrosion protection, allowing for flexible assembly and integration with bus-bars and circuit boards without pre-designing for specific mating structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple electrical connectors are used to implement electrical connections in battery cells, then electrical connection performance is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The electrical connector is divided into a first connector and a second connector that are independently formed elements, each with specific connecting portions and protruding end portions. This segmentation allows for modular assembly where connectors can be independently manufactured and then combined through the retainer, simplifying the overall assembly process while maintaining reliable electrical connections between battery cells.
Solution Approach 2:
The retainer is designed to be integrally interconnected with both the first connector and the second connector, creating a universal assembly structure that can accommodate different connector configurations. This multi-functional design allows the same retainer structure to hold various connector types, reducing the need for custom-designed assemblies for each specific connection scenario.
2Adaptability or versatility
If connectors made of different metal materials are used, then electrical connection versatility is improved, but electrochemical corrosion occurs
Solution Approach 1:
The retainer serves as an intermediary structure that holds both the first connector and the second connector made of different metal materials. By providing a protective enclosure and structured mounting mechanism, the retainer isolates the different metal surfaces and prevents direct contact that would facilitate electrochemical corrosion, while still allowing both connector types to function for their intended electrical connections.
Solution Approach 2:
The electrical connection assembly combines different metal materials (first connector and second connector made of different metals) within a unified retainer structure. This composite approach allows the system to leverage the advantages of different metals (such as aluminum for lightweight connections and copper for high conductivity) while the retainer provides a protective environment that prevents galvanic corrosion between the dissimilar metals.
3Reliability
If connectors are pre-designed for specific mating structures, then connection stability is improved, but universal flexibility is reduced
Solution Approach 1:
The retainer is designed as a universal mounting structure that can accommodate both the first connector with its first protruding end portion and the second connector with its second protruding end portion. This universal design allows the same retainer assembly to work with various connector configurations and mating structures, providing adaptability while maintaining stable connections through the standardized retainer interface.
Solution Approach 2:
The connector design allows for flexible adaptation to different mating structures through the protruding end portions that can be configured for different connection types (such as press-fit, welding, or other electrical connections). This dynamic design capability enables the same basic connector-retainer assembly to be adapted for various application requirements without sacrificing connection stability.
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 high universal flexibility, reduces manufacturing complexity, prevents electrochemical corrosion, and enhances the stability and longevity of electrical connections, thereby lowering assembly difficulties and maintaining integral structure integrity.
Implementation Method 1
The second connecting portion is connected to the first connecting portion by welding
Data Source
AI summary
The present disclosure provides an electrical connector and an electrical connection assembly. The electrical connector has a first connector, a second connector, and a retainer. The first connector has a first connecting portion and a first protruding end portion that are integrally connected with each other. The second connector has a second connecting portion and a second protruding end portion that are integrally connected with each other. The second connector and the first connector are independently formed elements, respectively. The retainer is integrally interconnected with the first connector and the second connector. The second connecting portion is electrically connected with the first connecting portion. The first protruding end portion is arranged to protrude from the retainer to electrically connect a first mating connector. The second protruding end portion is arranged to protrude from the retainer to electrically connect a second mating connector. The electrical connector of the present disclosure as a modularized assembly may be applied to a plurality of scenarios and thus has extremely high universal flexibility.