Battery Pack Lever Latch for Vibration-Resistant Swapping

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Solution Overview

Problem

Existing battery locking mechanisms in electric vehicles are cumbersome, prone to damage, and unsafe due to manual handling, leading to connector damage, vibrations, and increased range anxiety, with a need for a safer, reliable, and easy-to-use lock mechanism for swappable batteries.

Innovation Solution

A battery pack with a lever and latching unit on the front and rear portions, respectively, for easy engagement and disengagement, along with heat-dissipating fins and guide members, allowing secure and vibration-resistant installation and swapping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual handling of battery locking mechanisms is used, then ease of operation is improved, but reliability deteriorates due to connector damage and vibrations

Engineering Contradiction:

Improveease of operationVSAvoidreliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces manual mechanical locking mechanisms with an automated locking system that uses electrical actuators to engage and disengage locking members. This substitution eliminates the need for manual handling, thereby maintaining ease of operation while significantly improving reliability by preventing connector damage and vibrations associated with manual manipulation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The locking mechanism is designed to automatically engage and disengage without requiring manual intervention. The system uses electrical signals to activate actuators that perform the locking and unlocking functions autonomously, ensuring reliable operation while maintaining user convenience through simple button or switch activation.

Inventive Principle:

Principle #25Self-service

2Device complexity

If existing locking mechanisms are used, then device complexity is reduced, but ease of operation deteriorates due to cumbersome manual handling

Engineering Contradiction:

Improvedevice complexityVSAvoidease of operation

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent replaces complex manual locking operations with a simplified electrical actuation system. By using electrical motors or solenoids to perform the locking function, the system reduces the mechanical complexity of manual handling while dramatically improving ease of operation through automated control via simple user inputs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If manual battery swapping is used, then productivity is improved through direct handling, but reliability deteriorates due to connector damage and vibrations

Engineering Contradiction:

ImproveproductivityVSAvoidreliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements automated locking and unlocking mechanisms that enable rapid battery swapping without manual intervention. The electrical actuators engage and disengage locking members quickly and reliably, maintaining high productivity while eliminating connector damage and vibrations caused by manual handling, thus improving overall system reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If secure locking is implemented, then reliability is improved, but device complexity increases due to additional locking components

Engineering Contradiction:

ImprovereliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses electrical actuators to replace complex mechanical locking systems. This substitution maintains high reliability through automated, precise control of locking members while reducing overall device complexity by eliminating the need for complex manual operating mechanisms and reducing the number of mechanical parts that require maintenance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables safe, reliable, and convenient swapping of batteries, reducing vibrations and connector damage, enhancing vehicle availability, and reducing range anxiety by allowing quick battery exchange.

Implementation Method 1

A battery pack with a lever and latching unit on the front and rear portions, respectively, for easy engagement and disengagement

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

heat-dissipating fins and guide members, allowing secure and vibration-resistant installation and swapping

Methodology Applied

Scientific EffectHeat dissipation: Heat Sink

Implementation Method 3

heat-dissipating fins and guide members, allowing secure and vibration-resistant installation and swapping

Methodology Applied

Scientific EffectVibration resistance: Damping

Data Source

PatentUS20250219227A1A system of fastening a battery pack

Publication Date: 2025.07.03 TVS MOTOR CO LTD

AI summary

A battery pack includes: a lever on a front portion of the battery pack; and a latching unit operably connected to the lever. The lever actuates engagement and disengagement of the battery pack with an enclosure. The latching unit is disposed at a rear portion of the battery pack and is configured to engage and disengage the battery pack from the enclosure.