Elastic Battery Connector Structure for Weld-Free Core Replacement
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Solution Overview
Problem
Conventional battery devices face difficulties and risks during recycling or partial replacement due to complex and risky dismantling of welded guide strips, which can damage the electric core or lead to explosions.
Innovation Solution
A battery device with an elastic conductive element featuring a plate body, bend portions, connecting portions, and end portions that elastically abut against electric cores, ensuring electrical reliability without welding, and a control module for monitoring and controlling power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding machine is used to weld metal sheet and electric core, then electrical reliability is ensured, but dismantling becomes complex and risky
Solution Approach 1:
The guide strip is divided into a metal sheet portion and an elastic conductive element portion that can be easily separated. The elastic conductive element is designed with bend portions and connecting portions that allow it to be detached from the electric core without damaging other components, resolving the dismantling complexity issue while maintaining electrical connection reliability during operation.
Solution Approach 2:
The patent replaces the welding mechanical system with an elastic mechanical connection system. Instead of using welding machines to create permanent bonds, the invention uses elastic deformation and mechanical abutment of the guide strip against the electric core, enabling reliable electrical connection during operation but easy dismantling when needed.
2Reliability
If guide strips are welded to electric core, then electrical connection is achieved, but risk of damage or explosion increases during dismantling
Solution Approach 1:
The guide strip is segmented into detachable portions including the elastic conductive element that can be removed independently from the electric core. This segmentation allows the electrical connection to be established during operation while enabling safe removal during maintenance without risking damage to the electric core or surrounding components.
Solution Approach 2:
The welding process is replaced with a mechanical elastic connection system where the guide strip abuts against the electric core through elastic deformation. This eliminates the harmful effects of welding during dismantling operations, as no cutting or heating tools are needed to separate the components.
3Reliability
If welding is used for connection, then electrical reliability is ensured, but recycling process becomes complex and time-consuming
Solution Approach 1:
The guide strip is designed as a segmented structure with the elastic conductive element that can be quickly removed from the electric core. This segmentation enables rapid dismantling during recycling operations, allowing multiple guide strips to be removed in sequence without complex procedures, thereby significantly improving recycling efficiency while maintaining electrical reliability during battery operation.
Solution Approach 2:
The elastic mechanical connection system replaces welding, enabling the guide strip to be detached by simple manual or automated manipulation without requiring welding machines, cutting tools, or complex dismantling procedures. This substitution dramatically accelerates the recycling process while ensuring that electrical connections remain reliable during battery operation.
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 elastic conductive element achieves ideal electrical reliability and improved heat dissipation through non-welding connections, enhancing safety and ease of recycling.
Implementation Method 1
Each of the connecting portions and the plate body portion are spaced apart from each other, so as to have a first height change that gradually increases from the bend portions on a center area of the plate body portion. Each of the end portions is configured to elastically abut against a corresponding one of the electric cores through the connecting portions.
Data Source
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AI summary
A battery device (100) and an elastic conductive element (34) thereof are provided. The elastic conductive element (34) includes a plate body portion (341), a plurality of bend portions (342), a plurality of connecting portions (343), and a plurality of end portions (344). The bend portions (342) extend from the plate body portion (341). The connecting portions (343) respectively extend from the bend portions (342). Each of the connecting portions (343) and the plate body portion (341) are spaced apart from each other, so as to have a first height change (H1). The end portions (344) respectively extend from the connecting portions (343), so as to elastically abut against a corresponding one of the electric cores through the connecting portions (343).