Battery Assembly Self-Locating Mechanical Connection
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Solution Overview
Problem
Conventional battery pack designs lack self-locating mechanical elements for increased structural integrity during transportation and fail to reduce weight or manufacturing costs effectively.
Innovation Solution
A battery assembly with a self-locating mechanical connection between cells, featuring a boss and seat mechanism that prevents relative movement and eliminates the need for connecting hardware like electrical studs, combined with efficient packaging configurations such as overlapping and vertical stack arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional battery pack designs are used with separate connecting hardware, then assembly flexibility is maintained, but weight increases and manufacturing costs rise
Solution Approach 1:
The patent combines the mechanical connection function and electrical connection function into a single integrated tab structure. The tab serves dual purposes: it provides structural support for mechanical attachment between cells and simultaneously serves as the electrical conductor for current flow. This eliminates the need for separate mechanical fasteners and electrical connectors, thereby reducing weight and component complexity while maintaining both mechanical and electrical connectivity.
Solution Approach 2:
The tab is designed as a multi-functional component that performs multiple roles: it acts as an electrical conductor for current flow, a mechanical support structure for attachment, and a positioning element for aligning cells during assembly. This universal component replaces what would traditionally require separate specialized parts for each function, reducing overall system complexity and weight.
2Reliability
If battery cells are transported without self-locating mechanical elements, then packaging simplicity is maintained, but structural integrity during transportation deteriorates
Solution Approach 1:
The mechanical connection structure is integrated into the tab itself, which is already a necessary component for electrical connectivity. The tab's extended structure provides built-in mechanical attachment features that engage with corresponding structures on adjacent cells, creating self-locating connections that ensure proper alignment and structural integrity during transportation without requiring separate mechanical fasteners.
Solution Approach 2:
The tab structure is designed to automatically provide both electrical and mechanical functions without requiring additional components or complex assembly procedures. The integrated design allows the tab to self-locate and self-secure adjacent cells during assembly and transportation, eliminating the need for external positioning or securing mechanisms.
3Productivity
If multiple separate components are used for mechanical and electrical connections, then assembly precision can be optimized for each component, but manufacturing cost and assembly time increase
Solution Approach 1:
By integrating mechanical and electrical connection functions into the single tab structure, the patent reduces the number of assembly steps. Instead of separately installing mechanical fasteners and electrical connectors, the tab is attached in a single operation that simultaneously establishes both mechanical attachment and electrical connectivity, thereby increasing assembly speed and reducing manufacturing costs.
Solution Approach 2:
The multi-functional tab reduces inventory requirements and simplifies supply chain management by consolidating what would traditionally require multiple different components. This universal component can be manufactured and installed as a single part, reducing manufacturing complexity and assembly time while maintaining the functional requirements for both mechanical and electrical connections.
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 solution enhances structural integrity during transportation, reduces weight by eliminating unnecessary hardware, and simplifies assembly, leading to cost-effective manufacturing and improved packaging efficiency.
Implementation Method 1
a separator layer positioned between the first and second electrodes with the first and second electrodes conducting electrolyte therebetween
Implementation Method 2
The first and second cells present a mechanical connection defined therebetween. The mechanical connection presents a boss integral with and extending outwardly from the first insulator of the first cell through one of the contacts and beyond the shell of the first cell to mechanically engage a seat defined by the second insulator of the second cell
Implementation Method 3
as the tie rod or stud extends transversely through each contact thereby preventing relative movement between the first and second cells
Data Source
AI summary
A battery assembly includes a first cell and a second cell adjacent the first cell. A first insulator and a second insulator extend over and encapsulate first electrode and second electrode. A shell extends over the first and second insulators thereby encapsulating the first and second insulators. A mechanical connection is defined between the first insulator of the fist cell and the second insulator of the second cell.