Battery Pack Board Terminal Integration for Cost Reduction
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Solution Overview
Problem
Conventional battery packs have a complex structure with numerous components, leading to high costs, making motor-driven tools expensive due to the remote positioning of boards and terminals.
Innovation Solution
A simplified battery pack design featuring a housing with a board and second terminals, a cover that clamps between the board and housing, and protuberances and projected parts to prevent foreign material intrusion and short circuits, allowing for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the board and terminal are positioned remote from each other, then the terminal can be engaged with the second terminal, but the structure becomes complicated and production cost increases
Solution Approach 1:
The patent merges the board and terminal positioning into a unified structure where the terminal is directly mounted on the board at the opening side. This integration eliminates the need for separate remote positioning mechanisms and lead wires, thereby simplifying the overall battery pack structure while maintaining reliable electrical connection between terminals.
Solution Approach 2:
The board is designed to serve multiple functions: it acts as both the structural support for mounting the terminal and the electrical connection pathway. By making the board multi-functional, the patent reduces the number of separate components needed, simplifying the structure without compromising terminal engagement reliability.
2Reliability
If the board and terminal are positioned remote from each other, then the terminal can be engaged with the second terminal, but production cost increases
Solution Approach 1:
By combining the terminal mounting function directly onto the board at the opening side, the patent reduces component count and assembly steps. This merger eliminates the need for separate lead wires and remote mounting structures, thereby reducing production costs while maintaining reliable terminal engagement.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components (such as lead wires and remote positioning structures) from the traditional design. By removing these extraneous elements and directly mounting the terminal on the board, the design simplifies manufacturing processes and reduces production costs.
3Object-affected harmful factors
If the cover covers the board area between terminal arranging part and opening, then foreign material intrusion is prevented, but the structure becomes more complex
Solution Approach 1:
The cover is designed to perform multiple functions simultaneously: it protects the board from foreign material intrusion, provides structural support for terminal mounting, and maintains the sealed environment of the battery pack. By making the cover multi-functional, the patent prevents harmful effects without adding excessive structural complexity.
Solution Approach 2:
The patent merges the protective function against foreign materials with the structural support function into a single integrated cover component. This cover is positioned to simultaneously shield the board and provide mounting support, thereby preventing harm while avoiding the need for separate protective and structural elements.
Data Source
AI summary
A battery pack 10 includes a housing 11, a group of cells 12, a board 13, a plurality of second terminals 14, and a cover 15. An opening 16c is formed in the housing 11. The board 13 has a terminal arranging part 13A. A plurality of the second terminals 14 are arranged on the terminal arranging part 13A of the board 13. The cover 15 has a plate-like shape, and covers an area of the board 13 which is positioned between the terminal arranging part 13A and the opening 16c.