Battery Pack Electric Coupler Assembly Molding
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Solution Overview
Problem
The existing manufacturing process for rechargeable battery packs is cumbersome and expensive due to the complex and costly connection of individual battery cells to a circuit board, particularly for packs with cells sensitive to overcharging, which require separate monitoring and charging.
Innovation Solution
A system and method utilizing an electric coupler assembly with cell and circuit board couplings held by links that are cut after molding into a frame, allowing for individual electrical connections to each battery cell, simplifying and reducing the cost of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires or straps are used to connect individual battery cells to a circuit board, then individual electrical connections are achieved, but the manufacturing process becomes cumbersome and expensive
Solution Approach 1:
The patent merges multiple separate connection functions into a single integrated electric coupler assembly. This assembly includes multiple cell couplings and circuit board couplings connected by links, forming one molded unit that replaces the need for separate wires or straps for each cell connection, thereby simplifying the manufacturing process while maintaining individual electrical connections
Solution Approach 2:
The electric coupler assembly serves multiple functions simultaneously: it provides individual electrical connections to multiple battery cells, connects to the circuit board, and structures the internal wiring. This multi-functional component eliminates the need for separate connection elements for each cell, reducing manufacturing complexity and cost
2Reliability
If multiple separate connection elements are used for each battery cell, then individual cell monitoring is enabled, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple cell coupling elements and circuit board coupling elements into a single molded electric coupler assembly. The assembly maintains individual electrical pathways to each cell through its internal link structure, enabling cell-by-cell monitoring while presenting a single integrated component that reduces overall device complexity
Solution Approach 2:
The electric coupler assembly contains a nested structure where cell couplings are connected to each other through links, which are in turn connected to circuit board couplings. This nested arrangement of couplings within a single molded body achieves individual cell connections without requiring separate external connection elements for each cell
Data Source
AI summary
A battery pack including an electric coupling assembly. The battery pack includes a top housing, a bottom housing, a cell pad, a plurality of battery cells, a harness, and a circuit board. The harness includes a frame and electric coupler assembly having a plurality of internal and external electric couplings. The internal and external electric couplings include cell couplings and circuit board couplings. The internal and external couplings are held in place during manufacturing by links which are cut after the electric coupler assembly is molded into the frame.