Carrier With Conformal Positioning Structures For Battery Assembly
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Solution Overview
Problem
Existing battery module assembly methods are inconvenient due to the use of screws and accessories, which complicate the alignment and securement of battery assemblies in electric vehicles and bicycles.
Innovation Solution
A carrier design featuring a body with inserting grooves and positioning structures, including protrusions and recesses, allows for easy alignment and secure engagement of carriers, enabling versatile and expandable battery assemblies with convenient assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws and accessories are used to secure carriers, then the battery assemblies are fixed in position, but the assembly process becomes inconvenient and complex
Solution Approach 1:
The patent replaces the traditional screw-based mechanical fastening system with a positioning structure based on geometric profiling. The positioning protrusions and recesses with conformal geometric profiles enable direct mechanical engagement without requiring additional fastening components, thus substituting a complex mechanical system with a simpler geometric interlocking mechanism.
Solution Approach 2:
The patent merges the positioning and fastening functions into a single integrated structure. The positioning protrusions and recesses simultaneously achieve both alignment and securement of carriers, eliminating the need for separate screws and accessories. This merging of functions reduces the number of components and simplifies the assembly process.
2Reliability
If screws and accessories are used to secure carriers, then the battery assemblies are fixed in position, but the number of components increases
Solution Approach 1:
The patent extracts and eliminates unnecessary fastening components (screws and accessories) from the system by incorporating the fastening function directly into the carrier structure through geometric profiling. This extraction simplifies the overall structure by removing redundant parts while maintaining the essential fixing reliability.
Solution Approach 2:
The positioning structures with conformal geometric profiles serve multiple functions simultaneously: they provide positioning alignment, mechanical fastening, and structural integration. This multi-functionality reduces the need for specialized components and simplifies the overall device structure.
3Reliability
If traditional screw-based assembly is used, then carriers can be secured, but assembly and disassembly time increases
Solution Approach 1:
The positioning protrusions and recesses are pre-designed with conformal geometric profiles that automatically guide and align carriers during assembly. This preliminary geometric configuration enables rapid engagement without requiring manual alignment or complex fastening operations, significantly reducing assembly time.
Solution Approach 2:
The positioning structure allows for dynamic and reversible assembly. The geometric interlocking mechanism enables carriers to be quickly attached and detached without permanent fastening, facilitating rapid assembly and disassembly operations while maintaining secure connection during use.
Data Source
AI summary
A carrier includes a body, at least one first positioning structure and at least one second positioning structure. The body has a first side wall, a second side wall and a plurality of inserting grooves, and the inserting grooves are arranged side by side and located between the first side wall and the second side wall. The first positioning structure is disposed at the first side wall, and the second positioning structure is disposed at the second side wall. A geometric profile of the first positioning structure along a direction perpendicular to the first side wall is conformal with a geometric profile of the second positioning structure along a direction perpendicular to the second side wall. A battery assembly is also provided.