Clip-On Battery Pack Assembly Without Spot Welding

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Solution Overview

Problem

Existing DIY battery pack kits require expensive and dangerous spot welding techniques, are costly, and lack flexibility in design and safety, with mechanical stress potentially damaging cells and limiting power rating options.

Innovation Solution

A battery module or pack design using mechanical compression through clip-on parts that eliminate the need for spot welding and bolts, allowing easy assembly/disassembly and replacement of cells, using flexible conductive busbars and insulative plastic components for safer and cost-effective construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If spot welding techniques are used to connect battery cells, then reliable electrical connection is achieved, but the process becomes dangerous and costly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing safety and cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the thermal/mechanical spot welding process with a purely mechanical compression system. Clip-on parts apply compressive force to press battery cells against conductive busbars, creating reliable electrical connections through mechanical pressure rather than welding. This substitution eliminates the dangers and costs associated with spot welding while maintaining connection reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces clip-on parts as intermediary components that mediate between the battery cells and the conductive busbars. These clips serve as the connecting mechanism, applying controlled compression to ensure good electrical contact without requiring direct welding between cells and busbars, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Force

If nuts and bolts are used to compress battery cells with conductive bus bar, then mechanical compression is achieved, but the design becomes costly and dangerous

Engineering Contradiction:

Improvecompression force on battery cellsVSAvoidparts cost and safety

Core Design Contradiction:

ForceVSEase of manufacture

Solution Approach 1:

The patent employs simple, inexpensive clip-on parts that can be easily manufactured and replaced if needed. These clips are designed to be cost-effective alternatives to nuts and bolts, reducing overall parts cost while maintaining the necessary compression force. The simplicity of the clip design also enhances safety by eliminating complex fastening mechanisms.

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

Enables safer, cost-effective, and flexible battery pack assembly without spot welding, allowing easy cell replacement and design adjustments, while maintaining electrical contact under vibration, reducing mechanical stress, and lowering overall costs.

Implementation Method 1

The compressible conductive element may be compressed between the battery cell and the busbar

Methodology Applied

Scientific EffectMechanical compression: Compression

Data Source

PatentUS20260066416A1Battery module or pack

Publication Date: 2026.03.05 COOPER TRISTON

AI summary

A battery pack is described that does not require spot welding and does not require bolts to maintain contact compression of the individual battery cells. In one embodiment, each individual cell is a 18650 size lithium ion rechargeable battery cell, but the battery pack can use any size, type or shape individual battery cells with an easy modification of parts of the battery pack.