Modular Battery Assembly Skeleton with Snap-Fit Connectors
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Solution Overview
Problem
Existing battery assemblies face challenges in providing structural integrity and rigidity while simplifying the assembly process, often requiring complex and costly single-piece housings that are difficult to handle and store efficiently.
Innovation Solution
A battery assembly design utilizing a minimal number of modular components, including cell brackets connected to internal base and top plates, forming an external skeleton around battery cells, with snap fit connectors for easy assembly and a pre-assembled primary terminal assembly, reducing the need for individual electronics assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece housing is used to provide structural integrity, then structural strength is improved, but device complexity and handling difficulty increase
Solution Approach 1:
The housing is divided into multiple separate components including side walls, end walls, a base, and a cover, which can be manufactured independently and assembled together. This segmentation allows each component to be optimized for manufacturing while simplifying handling and assembly processes compared to a single-piece housing.
2Stability of the object's composition
If a single-piece housing is used, then structural rigidity is improved, but ease of manufacture and storage efficiency deteriorate
Solution Approach 1:
The housing is divided into multiple separate components including side walls, end walls, a base, and a cover, which can be manufactured independently and assembled together. This segmentation allows each component to be optimized for manufacturing while simplifying handling and assembly processes compared to a single-piece housing.
3Ease of operation
If multiple separate components are used to simplify assembly, then ease of assembly is improved, but structural integrity may deteriorate
Solution Approach 1:
The battery cells are positioned between the base and the cover, with the electrical circuit components integrated into the housing structure. This merging of functional elements within the modular housing structure maintains structural integrity while preserving assembly simplicity.
Solution Approach 2:
The battery cells and electrical circuit components are pre-positioned within the housing structure during assembly, ensuring proper alignment and structural integration before final assembly steps are completed.
4Adaptability or versatility
If individual electronics assembly is required, then adaptability is improved, but productivity and assembly time deteriorate
Solution Approach 1:
The electrical circuit components are integrated into the housing structure, combining the electronic assembly with the mechanical housing. This integration eliminates separate electronics assembly steps while maintaining the ability to configure different battery cell arrangements.
Data Source
AI summary
Battery assembly, comprising a primary positive battery terminal (20) and a primary negative battery terminal (22) connected by an electrical circuit, the electrical circuit comprising a series or parallel connection of one or more battery cells (14). The battery assembly (1) further comprises an external skeleton formed by an internal base plate (16), an internal top plate (18) and a plurality of cell brackets (24), surrounding the one or more battery cells (14).