Battery Pack Handle Rotary Coupling Mechanism

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Solution Overview

Problem

Existing battery packs face issues with handle separation during transportation, leading to potential electrical shorts and damage to the battery module, and have complex assembly processes that increase manufacturing costs.

Innovation Solution

A battery pack design featuring a handle unit that is rotary-coupled to the upper case at different angles using rotation supporting shafts and shaft hooks, allowing for secure attachment and simplified assembly through fit-coupling and rotary-coupling mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the handle is detachably coupled to the upper case, then the assembly process is simplified, but the handle separates from the upper case during transportation

Engineering Contradiction:

Improveassembly processVSAvoidhandle coupling stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The handle unit is designed to be rotatable relative to the housing, allowing it to transition between a horizontal transported state and a vertical used state. This dynamic positioning, combined with the rotary coupling mechanism, provides both ease of assembly and reliable coupling during transportation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The coupling mechanism is divided into multiple independent components: rotation supporting shafts on the housing, shaft hooks on the handle unit, and snap protrusions with snap grooves. This segmentation allows for simplified assembly while maintaining reliable coupling through the coordinated action of multiple simple elements.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the cases are screw-coupled to mount the portable handle, then the handle is securely attached, but the assembly process becomes complicated and manufacturing cost increases

Engineering Contradiction:

Improvehandle attachment securityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional screw-coupling mechanism is replaced with a rotary coupling system using shaft hooks and rotation supporting shafts, combined with snap-fit elements. This substitution eliminates the need for threading operations while providing equivalent or superior attachment security.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If the handle is fixated to the upper case, then the handle remains securely attached during use, but cracks generate in the contact portion of the upper case due to repeated stress

Engineering Contradiction:

Improvehandle attachment securityVSAvoidupper case contact portion integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The rotation supporting shafts act as intermediary elements between the housing and the handle unit's shaft hooks. This intermediary coupling mechanism distributes stress away from the upper case contact portions, preventing crack generation while maintaining secure attachment.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If the handle rotates relatively with respect to the cases through space between the cases, then the handle can be positioned for use, but the assembly process becomes very complicated

Engineering Contradiction:

Improvehandle positioningVSAvoidassembly process

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP3226323B1Battery pack

Publication Date: 2020.03.04 LG CHEM LTD

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AI summary

The present disclosure discloses a battery pack suitable for preventing simultaneous separation of both ends of a handle unit from an upper case during transportation of a lower case and the upper case that are laminated sequentially. The battery pack according to the present disclosure includes the lower case and the upper case stacked sequentially to encase a battery module, wherein the upper case includes a housing and a handle unit relatively rotated with respect to the housing to be seated on the housing, and the handle unit has shaft hooks that are penetrated by the rotation supporting shafts of the housing and that are each rotary-coupled to each of the rotation supporting shafts in different angles.