Battery Pack Coupler Isolation for 100 Wh Shipping Compliance
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Solution Overview
Problem
Conventional rechargeable battery packs often exceed the 100 Whr energy limit set by shipping regulations due to the increasing power and capacity of Li-Ion battery cells, leading to additional fees and shipping costs.
Innovation Solution
The battery pack is configured to isolate its strings of cells from each other, using a converting subsystem and a transport coupler/lock to decouple the cells, thereby limiting the energy output and ensuring compliance with shipping regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If battery power and capacity are increased to meet user energy needs, then energy availability is improved, but the battery pack exceeds the 100 Wh shipping limit requiring special handling
Solution Approach 1:
The battery pack is divided into multiple cell strings (first string, second string, third string) that can be independently connected or disconnected. During shipping, the isolating mechanism disconnects these strings, effectively segmenting the battery into separate units with lower individual energy content, thus complying with shipping regulations while maintaining the ability to provide high energy availability during normal operation when all strings are connected.
2Power
If multiple cell strings are connected in parallel to increase capacity, then energy output is improved, but the total energy exceeds shipping limits
Solution Approach 1:
The battery pack incorporates a dynamic isolating mechanism that can change the electrical connection state of cell strings based on operational requirements. During normal use, the mechanism allows parallel connection for maximum power output. During shipping, the mechanism dynamically isolates the strings, reducing the effective energy content to comply with regulations, thus providing adaptive behavior to satisfy both power and shipping constraints.
3Object-affected harmful factors
If a temporary separator is used to isolate cell strings during shipping, then shipping compliance is improved, but device complexity increases
Solution Approach 1:
An isolating mechanism acts as an intermediary component between the cell strings and the external environment. This mechanism includes conductive elements and insulating structures that can be engaged or disengaged to control electrical connectivity. The intermediary design allows for relatively simple integration into the existing battery pack structure while providing the necessary isolation functionality to comply with shipping regulations.
Data Source
AI summary
A battery pack and transport coupler for enabling the battery pack to reduce the pack power capacity. The battery pack include at least two strings of battery cells and a coupler provided at least partially inside the housing. The coupler is moveable between a first position, which causes the string of battery cells to be electrically connected inside the housing, and a second position, which causes the strings of battery cells to be electrically disconnected inside the housing