Battery Pack Electrical Connection Structure with Nested Securing

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Solution Overview

Problem

Lithium batteries are prone to ignition or explosion due to overheating or excessive charging, making it difficult to manufacture large high-voltage or high-current batteries, and securing elements in battery packs are easily loosened by external forces.

Innovation Solution

An electrical connection structure comprising an insulating unit, heat insulation unit, conductive unit, securing unit, and filling unit, where the securing elements are fixed using a sequence of holes and a filling material to prevent loosening, and a method for manufacturing this structure to enhance securing reliability in battery packs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional battery packs use simple securing elements to connect cells, then the device complexity is low and ease of manufacture is high, but the securing reliability deteriorates as elements loosen due to impact or shake

Engineering Contradiction:

Improvesecuring reliabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a nested structure where the securing element is inserted through multiple layers (first insulating layer, first heat insulation layer, second heat insulation layer, second insulating layer) forming a nested sequence of components. Each layer contains securing holes that align to guide the securing element, creating a nested arrangement that prevents loosening while maintaining structural organization.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent uses composite material structure combining multiple insulating materials (first and second insulating layers) and heat insulation materials (first and second heat insulation layers) with different properties. Each material layer serves specific functions: electrical insulation, thermal insulation, and mechanical securing, creating a composite structure that addresses multiple requirements simultaneously.

Inventive Principle:

Principle #40Composite materials

2Power

If lithium batteries are designed for high voltage or high current output, then the power output increases, but the risk of ignition or explosion increases due to overheating or excessive charging

Engineering Contradiction:

Improvepower outputVSAvoidoverheating risk

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The patent segments the battery pack structure into multiple functional layers: electrical insulating layers and heat insulation layers are separated and stacked alternately. This segmentation allows each layer to perform its specific function independently - electrical insulation prevents short circuits enabling higher current, while heat insulation prevents thermal runaway enabling higher power operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces heat insulation layers as intermediary components between battery cells. These intermediary layers act as thermal barriers that prevent heat accumulation and thermal runaway, allowing the battery system to operate at higher power levels without increasing overheating risk.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If multiple securing elements are used to prevent loosening, then the securing reliability improves, but the manufacturing time and complexity increase

Engineering Contradiction:

Improvesecuring reliabilityVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent designs the structure with pre-aligned securing holes in all layers before assembly. The first and second insulating layers and heat insulation layers are positioned such that their securing holes are pre-aligned, allowing the securing element to be inserted in a single continuous action through all layers, eliminating the need for multiple separate securing operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The securing element serves multiple functions simultaneously: it mechanically fastens all layers together, provides electrical isolation by passing through insulating layers, and enables thermal isolation by passing through heat insulation layers. This multi-functionality reduces the number of separate components needed, simplifying assembly while maintaining securing reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8753768B2Electrical connection structure for increasing the securing reliability and method of manufacturing the same, and battery pack structure

Publication Date: 2014.06.17 LITE ON TECH CORP

AI summary

An electrical connection structure includes an insulating unit, a heat insulation unit, a conductive unit, a securing unit, and a filling unit. The insulating unit includes an insulating body having a receiving groove and a first securing hole. The heat insulation unit includes a heat insulation body received in the receiving groove. The heat insulation body has a heat insulation groove and a second securing hole. The conductive unit includes a conductive body disposed on the insulating body. The conductive body has a securing piece extended into the heat insulation groove. The securing piece has a third securing hole. The securing unit includes a securing element sequentially passing through the third, the second, and the first securing holes for fixing the securing piece in the heat insulation groove. The filling unit includes a filling material received in the heat insulation groove to cover and fix the securing element.