Non-Coplanar Battery Connector Design for Vibration Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power battery module connectors, such as braided wires and lamination guide plates, face issues with high contact resistance, limited flexibility, and complex manufacturing processes, leading to reliability and space occupancy concerns, especially under vibration conditions.
Innovation Solution
A connector design featuring a main connection sheet divided into non-coplanar segments with angled fixing sheets, providing flexibility in three directions, replacing braided wires and simplifying manufacturing, while reducing contact resistance and enhancing vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If braided wires are used to connect power batteries, then flexibility is improved, but contact resistance increases and reliability decreases under vibration conditions
Solution Approach 1:
The connector is divided into a rigid connection body and a separate flexible connecting part with bending capability. This segmentation allows the flexible portion to absorb vibrations and mechanical stresses while the rigid body maintains stable electrical contact, resolving the contradiction between flexibility and vibration resistance.
2Adaptability or versatility
If lamination guide plates with multiple copper or aluminum foils are used, then flexibility is improved, but contact resistance increases due to multiple layers
Solution Approach 1:
The connector uses a composite structure combining rigid metal materials (copper or aluminum) for the connection body with a flexible material layer for the connecting part. This composite design provides both low contact resistance from the metal and flexibility from the flexible layer, eliminating the need for multiple foil layers.
3Ease of manufacture
If flat or arch connection sheets are used, then manufacturing is simplified, but flexibility and vibration resistance deteriorate
Solution Approach 1:
The connection sheet is designed with a dynamic flexible connecting part that can bend and deform elastically under vibration and mechanical stress. This dynamic capability allows the connector to adapt to dimensional changes and maintain reliable connection, overcoming the rigidity limitation of flat or arch-shaped sheets while keeping the manufacturing process simple.
4Ease of operation
If braided wires are pressed into connection ends, then connection is achieved, but contact resistance increases and space occupancy increases
Solution Approach 1:
The flexible connecting part is integrally formed with the connection body, merging the connection function and the flexible adaptation function into a single unified structure. This eliminates the need for separate pressing operations and reduces contact resistance by creating a continuous conductive path without mechanical deformation at connection points.
Data Source
Figure 1~2
Figure 3~4
AI summary
A connector (100) for power batteries, a power battery module, a power battery pack and a vehicle are provided. The connector (100) includes a main connection sheet, a first fixing sheet (10) and a second fixing sheet (20), in which the main connection sheet is divided into first to third connection segments (30,40,50), the first connection segment (30) and the second connection segment (40) are non-coplanar, the first fixing sheet (10) is connected with a side edge of the first connection segment (30) and a first predetermined angle is formed between the first fixing sheet (10) and the first connection segment (30), the second fixing sheet (20) is connected with a side edge of the second connection segment (40) and a second predetermined angle is formed between the second fixing sheet (20) and the second connection segment (40), and each of the first predetermined angle and the second predetermined angle is larger than 0 degree and less than 180 degrees.