Battery Module Connecting Element with Form-Fitting Recesses
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Solution Overview
Problem
The assembly of battery modules into a battery is complex, labor-intensive, and prone to incorrect alignment or assembly errors, particularly due to the need for precise positioning and connection of multiple modules in applications requiring high currents and voltages.
Innovation Solution
A battery design featuring at least two modules connected via a connecting element with end pieces and a middle piece, where the end pieces engage in peripheral recesses on the modules' housings in a form-fitting manner, ensuring precise alignment and secure connection, and allowing for easy assembly and subsequent adjustment or removal of modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment and assembly methods are used for battery modules, then flexibility in assembly is maintained, but the assembly process becomes complex and labor-intensive with prone to errors
Solution Approach 1:
The connecting element is divided into three distinct segments: a first end piece, a second end piece, and a middle piece connecting them. This segmentation allows each part to be independently designed and manufactured, simplifying the overall assembly process while maintaining precision through standardized interfaces.
Solution Approach 2:
The middle piece acts as an intermediary component between the two end pieces, providing a standardized connection interface that simplifies the assembly process. This intermediary element enables precise alignment and secure connection of battery modules without requiring complex manual adjustment procedures.
2Manufacturing precision
If form-fitting connecting elements are used to ensure precise alignment, then assembly precision is improved, but the device complexity increases due to additional components
Solution Approach 1:
The connecting element merges multiple functions into a single integrated component: alignment guidance through the middle piece, secure attachment through end pieces with engagement features, and structural support. This consolidation achieves precise alignment without requiring multiple separate alignment tools or adjustment mechanisms.
Solution Approach 2:
The form-fitting design of the connecting element enables self-alignment during assembly. The geometric features of the end pieces and middle piece automatically guide the battery modules into correct positions without requiring external alignment tools or manual adjustment, thereby achieving high precision while keeping the structure relatively simple.
3Stability of the object's composition
If secure connections are achieved through complex fastening mechanisms, then connection stability is improved, but the ease of assembly and disassembly deteriorates
Solution Approach 1:
The connecting element employs reversible engagement features that allow for easy insertion and removal. The end pieces are designed with features that provide secure attachment during operation but can be readily disengaged when needed, enabling dynamic adjustment of the battery system configuration without complex fastening or unfastening procedures.
Data Source
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AI summary
A battery (500) comprises at least two battery modules (100; 200, 300) which are held together by at least one connecting element (10; 50).It is proposed that: - a first battery module (100; 200) has a housing with at least one first marginal recess (101, 102; 201) on an outer surface of the housing; - a second battery module (100; 300) has a housing with at least one second marginal recess (101, 102; 302) on an outer surface of the housing; - the at least one connecting element (10; 50) holding the battery modules together comprises a first end piece (11; 51) and a second end piece (12; 52) and a central piece (13; 53) connecting the two end pieces; - the first end piece (11; 51) is designed as a retaining means and preferably engages positively in the first marginal recess (101, 102; 201) of the first battery module; and - the second end piece (12; 52) is designed as a holding means and preferably engages in a form-fitting manner in the second marginal recess (101, 102; 302) of the second battery module.