Modular Battery Stack Coupling Mechanism for Safe Transport
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Solution Overview
Problem
High-capacity batteries required for power-hungry devices like high-definition cameras and electric vehicles pose safety risks due to potential high currents, leading to travel restrictions on battery capacity, which limits their usage for devices needing more power.
Innovation Solution
A battery design featuring a mechanical coupling unit with pins and a capture element system allowing multiple batteries to be stacked, increasing capacity and current carrying capability while maintaining safety by keeping individual batteries below a predetermined safety limit, with locking elements and shielding to prevent accidental connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery capacity is increased to power high-definition cameras and electric vehicles, then the power supply capability is improved, but safety risks increase due to potential high currents
Solution Approach 1:
The patent divides a high-capacity battery system into multiple smaller battery units, each with capacity below the 100Wh safety threshold. These segmented batteries can be individually transported safely while being combined to provide the total power needed for high-definition cameras and electric vehicles, thus resolving the contradiction between power supply capability and safety risks during transport
2Quantity of substance
If multiple batteries are coupled together to form a battery stack, then the total capacity and current carrying capability are improved, but the device complexity increases
Solution Approach 1:
The coupling mechanism serves multiple functions simultaneously: it provides mechanical connection between batteries, establishes electrical connections through integrated contacts, and enables modular stacking configurations. This multi-functional design reduces the need for separate coupling and electrical connection systems, thereby reducing overall device complexity while allowing flexible battery stack configurations
Solution Approach 2:
The patent employs a nested coupling design where electrical contacts and mechanical coupling elements are integrated within each other. The electrical contacts are positioned within the mechanical coupling structure, allowing batteries to be stacked in a nested manner where each battery unit contains its own coupling and electrical connection system, simplifying the overall assembly process
3Ease of operation
If mechanical coupling pins are used for connecting batteries, then the ease of operation is improved, but the risk of accidental connections increases
Solution Approach 1:
The mechanical coupling pins are designed with asymmetric features including directional orientation elements and non-matching geometries between male and female coupling interfaces. This asymmetry ensures that batteries can only be connected in the correct orientation, preventing accidental reverse connections or improper mating, while still maintaining ease of operation through the simple insert-and-lock mechanism
Data Source
AI summary
A battery includes a first mechanical coupling unit and a second mechanical coupling unit. The first coupling unit includes a plurality of mechanical coupling pins (18). Each of the mechanical coupling pins (18) includes a pin head (22) and a pin shaft (20). The pin heads (22) have a greater diameter than the pin shafts (20). The second mechanical coupling unit includes a plurality of capture elements (24, 26) configured to capture heads of mechanical coupling pins of a first mechanical coupling unit.