Spring-Expanded Wire Braid Connector for Battery Module Spacing
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Solution Overview
Problem
The spacing between battery modules in a battery system can fluctuate due to manufacturing variations and thermal/mechanical loads, leading to high mechanical loads on rigid battery module connectors.
Innovation Solution
A flexible battery module connector with a wire braid and spring elements is used to compensate for spacing fluctuations, reducing mechanical loads and preventing gap formation between wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid battery module connectors are used, then structural stability is improved, but mechanical load on connectors and battery modules increases due to spacing fluctuations
Solution Approach 1:
The patent replaces rigid connectors with a dynamic wire braid structure that can flex and adapt to spacing changes. The wire braid's inherent flexibility allows it to dynamically adjust to thermal expansion and manufacturing tolerances, reducing mechanical stress while maintaining electrical connectivity.
Solution Approach 2:
The patent uses a flexible wire braid instead of rigid connector structures. The wire braid's flexible construction allows it to accommodate spacing fluctuations without transmitting high mechanical loads to the battery modules, while still providing stable electrical contact.
2Adaptability or versatility
If wire braid is compressed to compensate spacing fluctuations, then adaptability is improved, but gaps may form between wires leading to overheating
Solution Approach 1:
The patent incorporates a spring element within the wire braid structure that pre-compresses the wires together. This beforehand cushioning ensures that when the connector experiences spacing fluctuations, the wires remain in constant contact through the spring's continuous pushing force, preventing gaps that could lead to overheating or arcing.
Solution Approach 2:
The spring element acts as an intermediary between the wire strands, continuously pushing them together to maintain contact. This mediator ensures that the wires remain compressed and in contact even during compression or movement, preventing harmful gaps while allowing the overall structure to adapt to spacing changes.
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 flexible connector ensures secure electrical contacting, reduces mechanical stress, and minimizes overheating and spark formation, allowing for greater tolerance in spacing fluctuations.
Implementation Method 1
at least one spring element that is inserted into a section of the wire braid between the first end and the second end, and is configured to impinge the section with a spring force such that the section is widened radially with respect to a longitudinal axis of the wire braid
Data Source
AI summary
A battery module connector for electrically conductive connecting of two battery modules includes a first contact element for electrically conductive contacting of a first battery module, a second contact element for electrically conductive contacting of a second battery module, a band-shaped wire braid that is electrically conductively connected at a first end to the first contact element and at a second end to the second contact element, and at least one spring element that is inserted into a section of the wire braid between the first end and the second end, and is configured to impinge the section with a spring force such that the section is widened radially with respect to a longitudinal axis of the wire braid.