Spring-Loaded Battery Cell Contact Interface for Weld-Free Replacement
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Solution Overview
Problem
Existing battery pack designs for electric vehicles are complex and costly, with limited flexibility in cell arrangement and replacement, which hinders efficient reuse of battery cells at the end of their life for secondary applications.
Innovation Solution
A contact interface system comprising a bracket, conductive terminal contact plate, and biasing member that securely couples and decouples pairs of battery cells without damage, allowing for easy assembly, disassembly, and replacement, suitable for both prismatic and pouch-type cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are welded together to complete electrical paths, then electrical connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent divides the battery pack into modular units with standardized contact interfaces. Each module can be independently assembled and disassembled without welding, allowing the electrical connection system to be segmented into reusable components that simplify manufacturing while maintaining reliable connections through standardized mechanical-electrical contact structures.
Solution Approach 2:
The patent changes the connection method from permanent welding to reversible mechanical contact with spring-loaded terminals. This parameter change in the connection mechanism allows for easy assembly and disassembly while maintaining electrical reliability through controlled contact pressure and conductive material selection, thereby reducing manufacturing complexity.
2Reliability
If battery cells are permanently welded together, then electrical connection stability is improved, but ease of repair and replacement deteriorates
Solution Approach 1:
The patent employs dynamic spring-loaded contact terminals that maintain constant electrical pressure while allowing mechanical movement for assembly and disassembly. This dynamic mechanism ensures stable electrical connection during operation while enabling easy removal and replacement of battery cells, resolving the contradiction between connection stability and repairability.
Solution Approach 2:
The patent extracts the electrical connection function from permanent welding and separates it into a reusable contact interface component. This extracted contact interface can be removed and reused with different battery cells, allowing individual cells to be replaced without damaging the connection system, thereby improving ease of repair while maintaining electrical stability.
3Power
If complex battery pack designs are used to achieve required voltage and current, then power output is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent designs universal contact interfaces that can accommodate different battery cell types and configurations to achieve various voltage and current requirements. This multi-functional contact system eliminates the need for complex custom-designed connection structures for different power outputs, reducing manufacturing cost and device complexity while maintaining the ability to deliver required power levels.
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
Enables efficient reuse of battery cells by facilitating easy assembly and disassembly, reducing replacement costs, and allowing for the use of battery cells in secondary applications, while simplifying the assembly process and potentially reducing weight through the elimination of welding systems.
Implementation Method 1
a biasing member provided between the bracket and the terminal contact plate
Implementation Method 2
a conductive terminal contact plate configured to be in contact with terminals on the batteries
Data Source
AI summary
A contact interface is configured to be coupled to a pair of batteries. The contact interface includes a bracket, a conductive terminal contact plate and a biasing member provided between the bracket and the terminal contact plate. The bracket includes a base and a pair of legs extending from opposite ends thereof. Each leg has an engagement which is configured to be coupled to an engagement on each of the batteries. The terminal contact plate is configured to be in contact with terminals on the batteries. The biasing member biases the terminal contact plate into contact with the terminals.