Battery Pack Coupler for 100 Wh Shipping Compliance
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Solution Overview
Problem
Conventional rechargeable battery packs often exceed shipping regulations regarding Watt-hour limits, leading to additional fees and logistical challenges, as they typically consist of Li-Ion cells that exceed the 100 Wh limit, necessitating a solution to maximize energy while complying with regulations.
Innovation Solution
The battery pack is configured to isolate strings of cells, using a converting subsystem with a converter element that switches between parallel and series connections, allowing the pack to operate within the 100 Wh limit by decoupling or coupling the cells based on the required voltage configuration, including a transport configuration that isolates cells to meet shipping regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If battery capacity is increased to provide more energy to end users, then energy availability is improved, but the battery pack exceeds shipping regulations (100 Wh limit)
Solution Approach 1:
The battery pack incorporates a convertible configuration system that dynamically changes the electrical connection topology between cell strings based on operational needs. The system can switch between series connections (higher voltage, lower current) and parallel connections (lower voltage, higher current), allowing the same physical battery pack to adapt its electrical characteristics to meet different energy requirements while maintaining compliance with shipping regulations through proper cell isolation during transport.
2Power
If multiple strings of cells are connected in parallel to increase power output, then power rating increases, but the battery pack exceeds the 100 Wh limit requiring special shipping
Solution Approach 1:
The battery pack divides the cell array into multiple independent strings that can be electrically isolated from each other. Each string can be independently connected or disconnected through switching mechanisms. This segmentation allows the system to operate with multiple strings in parallel when high power is needed, while enabling complete isolation of strings during shipping to maintain compliance with 100 Wh limits and avoid special shipping requirements.
3Object-affected harmful factors
If a temporary separator is used to separate cell strings, then the battery pack circuit is opened and energy output is limited, but compliance with shipping regulations is achieved
Solution Approach 1:
The patent employs switching mechanisms and isolating components that act as intermediaries between cell strings. These intermediaries can be inserted or removed to control electrical connectivity. The switching system provides automated or manual control over whether cell strings are electrically connected or isolated, enabling seamless transition between operational modes (series/parallel) and transport mode (isolated) without requiring permanent physical separators or complex mechanical modifications to the battery structure.
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.