Battery Pack Fastening Module for Compact Assembly
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Solution Overview
Problem
Existing battery packs for hand power tools require complex assembly processes and multiple fastening components, leading to increased effort and expense, as well as potential space inefficiencies due to the need for separate fastening and locking mechanisms.
Innovation Solution
A fastening module within the battery pack that secures the locking unit to the battery cell, allowing for preassembly and integration into the base body, reducing assembly steps and components, and enabling a compact design through form-locking connections and contact-holding means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fastening means are used to secure the locking unit to the base body and battery cell, then reliable fastening is achieved, but assembly effort and component count increase
Solution Approach 1:
The patent combines the fastening means for the locking unit and the fastening means for the battery cell into a single integrated fastening module. This module includes a first fastening means with a first fastening element and a second fastening means with a second fastening element, both integrated into one component. This merging reduces the number of separate fastening components and simplifies assembly while maintaining reliable fastening of both the locking unit and battery cell to the base body.
2Reliability
If multiple separate fastening components are used, then secure fastening is achieved, but installation space increases
Solution Approach 1:
The fastening module integrates multiple fastening functions into a single compact component structure. The first fastening means and second fastening means are combined in one module, reducing the overall volume required for fastening mechanisms while maintaining secure fastening of both the locking unit and battery cell.
Solution Approach 2:
The fastening elements are arranged in a nested or space-efficient configuration within the fastening module. The first and second fastening means are integrated in a way that minimizes the space occupied by the fastening mechanism, allowing compact installation within the battery pack structure.
3Reliability
If complex fastening mechanisms are used, then reliable locking is achieved, but manufacturing cost increases
Solution Approach 1:
By integrating multiple fastening functions into a single fastening module, the patent reduces the total number of parts that need to be manufactured, inventoried, and assembled. This integration simplifies the manufacturing process and reduces costs while maintaining reliable locking through the combined first and second fastening means.
Solution Approach 2:
The fastening module serves multiple functions simultaneously: it fastens the locking unit to the base body, fastens the battery cell to the base body, and provides structural support. This multi-functionality reduces the need for separate specialized components, thereby lowering manufacturing complexity and cost.
4Reliability
If separate fastening modules are used for locking unit and battery cell, then individual fastening is achieved, but assembly time increases
Solution Approach 1:
The integration of first and second fastening means into a single fastening module allows both the locking unit and battery cell to be fastened simultaneously in one assembly operation. This eliminates the need for separate assembly steps for each component, thereby increasing assembly speed and productivity while maintaining reliable individual fastening of each component.
Solution Approach 2:
The fastening module is designed as a pre-assembled unit with both fastening means already integrated, allowing for preliminary preparation and testing before final installation. This pre-integration reduces on-site assembly time and complexity while ensuring proper fastening of both components.
Data Source
AI summary
In a battery pack for an electrical device having a base body, a locking unit for locking the base body to the electrical device, and at least one battery cell, the battery pack has a fastening module, which is intended for securing the locking unit to the battery cell.