Plug-In Cell Connector Terminal for Battery Cable Connections
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Solution Overview
Problem
Ultrasonic welding of wire harnesses to cell connector plates in batteries is unmanageable and requires an alternative solution.
Innovation Solution
An electrical sensor contacting element comprising a cell connector plate contact terminal and a complementary cell connector terminal that can be plugged together, eliminating the need for welding by using a single-layer, spring-loaded design made of aluminum for the contact terminal and a stiffer terminal, allowing for crimping or other attachment methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to connect wire harnesses to cell connector plates, then electrical connections are established, but the process becomes unmanageable and difficult to control
Solution Approach 1:
The patent replaces the ultrasonic welding process (thermal-mechanical system) with a mechanical plugging system. The contact terminal with plug-in contact elements directly engages with corresponding receptacles in the cell connector plate, eliminating the need for ultrasonic welding equipment and process control while ensuring reliable electrical connections through mechanical insertion and retention mechanisms.
2Reliability
If ultrasonic welding is used to connect copper inner conductors to aluminum cell connector plates, then electrical connections are established, but the process requires complex equipment and parameters
Solution Approach 1:
The invention substitutes the complex ultrasonic welding apparatus with a simple mechanical plugging system. The contact terminal assembly with integrated contact elements plugs directly into the cell connector plate, eliminating heterogeneous material welding (copper to aluminum) and replacing it with like-material or compatible-material mechanical connections that require no specialized welding equipment.
Solution Approach 2:
The patent divides the connection system into separate modular components: the contact terminal with its contact elements, the electrical cable, and the cell connector plate with receptacles. This segmentation allows each component to be optimized independently and connected through simple plugging, avoiding the need for complex welding processes to join dissimilar materials.
3Ease of manufacture
If a single-layer spring-loaded aluminum contact terminal is used, then ease of manufacture and flexibility are improved, but connection strength must be maintained
Solution Approach 1:
The patent utilizes the spring-loaded design of the contact terminal to dynamically adjust contact pressure parameters. The elastic spring mechanism maintains optimal contact force between the contact element and the receptacle, ensuring reliable electrical connection and mechanical strength while allowing for manufacturing tolerances and assembly variations. This parameter adjustment capability compensates for the simplicity of the single-layer aluminum construction.
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
This solution provides a reliable and efficient method for connecting electrical cables to cell connector plates without the difficulties of ultrasonic welding, ensuring secure and flexible connections suitable for battery applications in electric vehicles.
Implementation Method 1
The cell connector terminal receives the cell connector plate contact terminal by plugging
Data Source
AI summary
An electrical sensor contacting element includes a cell connector plate contact terminal for an electrical cable and a cell connector terminal at least partially complementary to the cell connector plate contact terminal. The cell connector terminal receives the cell connector plate contact terminal by plugging. The cell connector terminal is part of an electrical cell connector plate.