Spring-Loaded Wire Mesh Battery Module Connector for Tolerance Gaps
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Solution Overview
Problem
Rigid battery module connectors face mechanical stress due to varying distances between battery modules in electric vehicle systems, leading to potential gaps and excessive heating, which can cause damage and functional issues.
Innovation Solution
A flexible battery module connector featuring a band-shaped wire mesh with integrated spring elements that apply radial force to maintain wire tightness, allowing for secure electrical contact and compensating for distance fluctuations up to several millimeters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid battery module connectors (such as copper blocks) are used, then secure electrical contact is achieved, but strong mechanical stress occurs on the battery module connectors and battery modules due to distance variations
Solution Approach 1:
The patent replaces rigid copper block connectors with flexible wire mesh connectors that can accommodate distance variations between battery modules. The wire mesh structure inherently provides flexibility while maintaining electrical conductivity, eliminating the mechanical stress problem associated with rigid connectors.
Solution Approach 2:
The patent changes the physical state and mechanical properties of the connector material from rigid to flexible. By using wire mesh with specific geometric parameters and material properties, the connector can dynamically adapt its shape to accommodate distance fluctuations while maintaining reliable electrical contact.
2Stress or pressure
If flexible wire mesh is used to accommodate distance fluctuations, then mechanical stress is reduced, but gaps may form between wires when compressed leading to excessive heating
Solution Approach 1:
The patent applies preliminary compressive force to the wire mesh structure during installation or assembly. This pre-compression ensures that the wires remain in constant contact even when the connector is subjected to additional compression from distance variations, preventing gap formation and the associated heating problems.
Solution Approach 2:
The wire mesh structure is designed with inherent cushioning characteristics that allow it to absorb compression forces without collapsing or forming gaps. The geometric configuration and material selection provide built-in compliance that maintains wire contact under varying loads.
3Object-affected harmful factors
If spring elements are inserted into wire mesh to apply radial force and prevent gaps, then wire tightness is maintained, but device complexity increases
Solution Approach 1:
The patent combines the spring element functionality directly into the wire mesh structure itself. Rather than adding separate spring components, the wire mesh is configured to provide both structural support and spring-like compliance, integrating multiple functions into a single unified structure.
Solution Approach 2:
The wire mesh serves multiple functions simultaneously: it provides electrical conductivity, mechanical flexibility, gap prevention through radial spring force, and structural support. This multi-functionality eliminates the need for separate components and reduces overall device complexity.
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 reduces mechanical stress and prevents gaps between wires, minimizing the risk of overheating and damage, ensuring reliable and durable electrical connections across varying tolerances.
Implementation Method 1
at least one spring element which is inserted into a section of the wire mesh between the first end and the second end and is designed to apply a spring force to the section such that the section is expanded radially to a longitudinal axis of the wire mesh
Data Source
Figure 1a~1b
Figure 2~3
AI summary
The invention relates to a battery module connector (106) for electrically connecting two battery modules (102, 104). The battery module connector (106) comprises a first contact element (108) for electrically connecting a first battery module (102), a second contact element (110) for electrically connecting a second battery module (104), a ribbon-shaped wire mesh (112) which is electrically connected at its first end to the first contact element (108) and at its second end to the second contact element (110), and at least one spring element (114) which is inserted into a section of the wire mesh (112) between the first end and the second end and is configured to exert a spring force on the section such that the section is stretched radially towards a longitudinal axis (116) of the wire mesh (112).