Plastic Battery Cell Carrier With Integrated Spring Tolerance Fit
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Solution Overview
Problem
Existing battery cell carriers are difficult and expensive to produce due to the need for precise fitting and tolerance compensation between the cylinder chambers and battery cells.
Innovation Solution
A spring element integrated with the battery cell carrier, which can be deflected radially outward, compensates for tolerances between the cylinder chambers and battery cells, allowing for a single-piece, cost-effective production using plastic injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise fitting and tolerance compensation mechanisms are added to ensure secure battery cell enclosure, then reliability of battery cell protection is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the physical state and geometric parameters of the carrier material by incorporating elastomeric properties and spring elements. These parameter changes allow the carrier to dynamically adapt to tolerance variations in battery cell dimensions, providing secure enclosure without requiring complex precision fitting mechanisms.
Solution Approach 2:
The patent employs flexible elastomeric material for the carrier body and spring elements that can deform radially outward. This flexibility allows the carrier to accommodate tolerance variations in battery cell dimensions while maintaining secure enclosure, eliminating the need for rigid precision-fit structures.
2Reliability
If precise fitting and tolerance compensation mechanisms are added to ensure secure battery cell enclosure, then reliability of battery cell protection is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the carrier body and spring elements into a single integrated component made from elastomeric material. This combination eliminates the need for separate tolerance compensation mechanisms and reduces assembly steps, thereby lowering manufacturing cost while maintaining reliable battery cell enclosure.
Solution Approach 2:
By changing the material parameters to elastomeric composition with inherent spring properties, the patent achieves tolerance compensation through material behavior rather than complex mechanical structures. This approach simplifies manufacturing processes and reduces production costs while ensuring secure battery cell protection.
3Ease of manufacture
If press fit design is used to secure battery cells, then ease of manufacture is improved, but harmful factors increase due to potential damage to battery cells
Solution Approach 1:
The patent uses flexible elastomeric material with spring elements that can deform radially outward to accommodate battery cells. This flexible approach replaces rigid press fit designs, maintaining ease of manufacture while eliminating the harmful impact forces that could damage battery cell seals or structures.
Solution Approach 2:
The spring elements are pre-configured to provide cushioning and tolerance compensation before battery cells are inserted. This beforehand cushioning prevents excessive contact forces and potential damage to battery cells during insertion and operation, while maintaining simple manufacturing processes.
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
Ensures simple and cost-effective production of battery cell carriers while avoiding undesirable press fits, ensuring secure enclosure of battery cells without additional elastomer parts.
Implementation Method 1
a spring element which can be deflected radially outwards and is formed integrally with the battery cell carrier is arranged on an inner circumferential surface of each cylinder chamber in order to compensate for a tolerance between the cylinder chamber and the battery cell
Data Source
Figure 1
AI summary
Battery cell carrier for a battery pack of an electric hand tool, wherein the battery cell carrier is made of plastic and has a plurality of cylinder chambers arranged parallel to one another, into each of which a cylindrical battery cell can be inserted in the axial direction, wherein on an inner circumferential surface of each cylinder chamber there is arranged a spring element which can be deflected outwards in the radial direction and is formed integrally with the battery cell carrier to compensate for a tolerance between the cylinder chamber and the battery cell.