Battery Pack Cell Holder Casting for Faster Assembly and Protection
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Solution Overview
Problem
Existing battery pack structures for electrically driven work appliances face challenges in efficient production and assembly, particularly in securely holding and connecting battery cells and electronics, leading to potential faults and complexity in manufacturing.
Innovation Solution
A battery pack structure featuring cell holder parts that form a filling mould for protective material and integrate casted cell contactors, allowing for a synergistic effect that simplifies production by forming a predominant part of the filling mould and enabling direct contact with battery cells, thus reducing assembly steps and potential faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional separate components for cell holding and electronics protection are used, then manufacturing flexibility is maintained, but device complexity and assembly time increase
Solution Approach 1:
The patent combines multiple separate components (cell holder parts and electronics protection structure) into an integrated assembly where the cell holder parts form both the cell holding structure and the filling mould for electronics protection. This merging reduces the number of separate parts and simplifies the overall device structure while maintaining manufacturing flexibility through modular cell holder parts that can be produced separately and assembled.
Solution Approach 2:
The cell holder parts serve multiple functions: they hold the battery cells, form the filling mould for protective material, and provide structural support for the electronics. This multi-functionality reduces the need for separate dedicated components, thereby reducing device complexity without compromising ease of manufacture.
2Productivity
If multiple separate assembly steps are used for cell holding and electronics protection, then manufacturing precision can be maintained, but productivity decreases
Solution Approach 1:
The patent merges the cell holding function and electronics protection function into a single integrated assembly step. The cell holder parts are configured to form both structures simultaneously, allowing both components to be assembled together in one operation rather than requiring multiple separate assembly steps, thereby increasing productivity while maintaining precision through the integrated design.
Solution Approach 2:
The cell holder parts are pre-configured with integrated features that enable them to form both the cell holding structure and the filling mould. This preliminary integration of functions into the component design allows for faster assembly without sacrificing precision, as the precise geometric relationships are built into the parts themselves rather than requiring multiple alignment steps.
3Reliability
If traditional wiring harness connections are used for cell contactors, then electrical connectivity is achieved, but device complexity and potential fault points increase
Solution Approach 1:
The patent extracts the cell contactor function from the traditional wiring harness system and integrates it directly into the cell holder parts. This removes the need for separate wiring harness connections, reducing device complexity and the number of potential fault points while maintaining reliable electrical contact through the integrated contactor design that is permanently associated with the cell holding structure.
Data Source
AI summary
A structure for a battery pack for supplying an electrically driven work appliance with electrical drive power has a number of cell holder parts. The number of cell holder parts is designed for holding battery cells. At least two cell holder parts are designed for arrangement together in a holding arrangement and, in the holding arrangement, for jointly holding the battery cells. The cell holder parts, in the holding arrangement, jointly form at least a predominant part of a filling mould. The filling mould is designed for filling with a protective material for enclosing at least a part of a battery pack electronics unit. Additionally or alternatively, the structure has at least one cast assembly, wherein the cast assembly unites one of the number of cell holder parts and at least one casted-in cell contactor. The cell contactor is designed for contacting at least one cell terminal of at least one of the held battery cells.