Battery Pack Spring Contact Assembly for Safe Cell Replacement

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery packs face difficulties in safely and easily disassembling and reusing battery cells due to welding failures or abnormal states, leading to potential short circuits and loss of function.

Innovation Solution

Incorporating compressed springs between the case and current collecting plates, along with claws for safe assembly and disassembly, allowing battery cells to constantly contact the plates and enabling easy replacement and reuse without impairment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery cells are welded to current collecting plates, then electrical connection is achieved, but disassembly becomes difficult and may impair cell shape or electrical characteristics

Engineering Contradiction:

Improveelectrical connectionVSAvoiddisassembly

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent divides the connection system into separable components: current collecting plates are detached from battery cells and replaced with spring-based contact members. This segmentation allows the electrical connection system to be divided into replaceable parts, enabling easy disassembly and replacement of individual components without damaging the battery cells.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces spring-based contact members as intermediary elements between the current collecting plates and battery cells. These springs serve as mediators that provide both electrical connection and mechanical retention forces, replacing the direct welding connection with an intermediate spring mechanism that facilitates easy disassembly while maintaining reliable electrical contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If battery cells are securely fixed in the case, then stability is improved, but disassembly and replacement of cells becomes difficult

Engineering Contradiction:

Improvecell fixationVSAvoidcell replacement

Core Design Contradiction:

Stability of the object's compositionVSEase of repair

Solution Approach 1:

The patent transforms the static fixed connection into a dynamic spring-based connection. The spring contact members can be compressed during assembly to secure cells firmly, then easily released during disassembly. This dynamic mechanism provides both secure fixation during operation and easy removal when needed, resolving the contradiction between stability and ease of replacement.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent incorporates preliminary retention actions through spring pre-compression and claw structures that automatically engage with cell features during assembly. These preliminary actions secure cells in place during normal operation, while the same mechanisms can be easily reversed or disengaged when cell replacement is needed, providing both secure fixation and easy removal.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If welding is used to connect battery cells to current collecting plates, then electrical characteristics are maintained, but manufacturing complexity increases due to quality control requirements

Engineering Contradiction:

Improveelectrical characteristicsVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical joining) with a spring-based mechanical contact system. This substitution eliminates the need for welding operations, equipment, and quality control procedures while maintaining reliable electrical connection through spring pressure and conductive contact, significantly simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs relatively simple spring contact members that can be easily manufactured and replaced if needed, rather than requiring complex welding operations. The springs serve as disposable or easily replaceable components that simplify manufacturing by eliminating the need for skilled welding operations and complex quality control.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Facilitates safe and easy disassembly and reuse of battery cells, improving the yield of battery packs by allowing faulty cells to be replaced, and extending the life of battery cells for other applications.

Implementation Method 1

compressing the springs (6) in advance, thereby connecting the battery cells (2) and the current collecting plates (4, 5) to each other by a force of returning the springs (6) to an original length

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9680138B2Battery pack

Publication Date: 2017.06.13 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

Battery cells are fixed by a cell holder and are housed inside a case in a state where both electrodes are sandwiched by a positive-electrode current collecting plate and a negative-electrode current collecting plate, and springs are arranged above and under the current collecting plates. Claws are provided on side surfaces of the case, which can temporarily fix the springs to the current collecting plates at the time of assembly and prevents the case from being ejected suddenly when a fastener is released at the time of disassembly.