Magnetic Battery Cell Fixing in Packs Without Welding
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Solution Overview
Problem
Current battery packs for medium and large-sized devices require complex and time-consuming welding to connect and fix multiple battery cells, making it difficult to replace damaged cells and potentially affecting performance and safety due to welding intensity.
Innovation Solution
A battery pack design utilizing a magnetic force to easily fix and replace battery cells, featuring a fixing unit with magnetized first and second members that attach to the cells and housing, allowing for secure positioning and electrical connection without welding, enabling quick replacement and reduced manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect and fix battery cells, then structural stability and electrical connection are achieved, but manufacturing time increases and complexity increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a magnetic fixing system. Magnets are positioned to hold battery cells in place through magnetic attraction, eliminating the need for welding operations while maintaining structural stability and enabling quick assembly and disassembly.
Solution Approach 2:
The fixing structure is divided into separate magnetic components that can be independently positioned and adjusted. This segmentation allows for modular assembly where magnets can be strategically placed at different locations to secure multiple battery cells without requiring complex welded joints.
2Reliability
If welding is used to fix battery cells, then structural stability is achieved, but ease of repair deteriorates
Solution Approach 1:
The magnetic fixing system replaces permanent welded connections with reversible magnetic attraction. This allows damaged battery cells to be easily removed by simply overcoming the magnetic force, enabling quick replacement and repair without cutting or breaking welded joints.
Solution Approach 2:
The fixing system transitions from a static welded connection to a dynamic magnetic connection that can be easily activated and deactivated. This dynamic characteristic enables the system to maintain stable fixation during operation while allowing rapid disassembly for repairs by simply removing or repositioning the magnetic components.
3Reliability
If welding is used to connect battery cells, then electrical connection is achieved, but harmful factors increase
Solution Approach 1:
The patent replaces the welding process with a magnetic fixing system that provides mechanical holding without thermal input. This eliminates harmful welding effects such as heat-affected zones, potential cell deformation, and safety risks associated with high-intensity welding operations while maintaining reliable electrical connections through proper contact design.
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
The magnetic fixing unit simplifies the assembly and maintenance of battery packs, reducing manufacturing time and costs, while ensuring the performance and safety of the battery pack by eliminating the need for welding and allowing for easy replacement of damaged cells.
Implementation Method 1
a fixing unit disposed in the battery pack housing to fix a position of the plurality of battery cells by using a magnetic force
Data Source
AI summary
A battery pack, a manufacturing method thereof, and a method for replacing a battery cell of the battery pack are provided. The battery pack includes a battery pack housing, a plurality of battery cells in the battery pack housing, and a fixing unit in the battery pack housing and configured to fix a position of the plurality of battery cells by a magnetic force.