Elastic Battery Module Connection for Automated Atomizer Assembly

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Solution Overview

Problem

The high material costs and low efficiency in manufacturing atomizers due to the use of tin for electrical connections between batteries and main control boards, which require manual welding and are difficult to automate.

Innovation Solution

The implementation of an elastic conduction sheet made of iron, which connects the battery to the main control board, allowing for automated welding and reducing material costs by eliminating the need for tin, while also providing elasticity to adapt to position errors and thermal expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If tin welding is used to connect lines to battery and main control board, then electrical connection is achieved, but material costs increase and automation becomes difficult

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing automation capability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from tin to iron for the conduction sheet, and changes the connection method from line welding to sheet welding. This parameter change enables automation while maintaining reliable electrical connection between battery and main control board

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces expensive tin material with cheaper iron material for the conduction sheet. This substitution reduces material costs while the elastic design ensures sufficient service life for the connection

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If manual welding is used for thin line ends, then electrical connection is achieved, but manufacturing efficiency decreases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent segments the connection structure into an elastic conduction sheet with distinct welding areas at both ends. This segmentation allows each end to be independently welded to different components (battery and main control board), enabling automated welding processes and improving manufacturing efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The elastic conduction sheet acts as an intermediary component between the battery and main control board. This intermediary enables reliable electrical connection while its elastic properties accommodate position errors, allowing automated assembly without manual adjustment

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If rigid connection is used between battery and main control board, then structural stability is achieved, but adaptability to position errors and thermal expansion is reduced

Engineering Contradiction:

Improvestructural stabilityVSAvoidadaptability to position errors and thermal expansion

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent transforms the rigid connection into a dynamic connection using an elastic conduction sheet. The sheet can deform elastically under stress, allowing the connection to adapt to position errors and thermal expansion while maintaining structural stability during normal operation

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses a thin elastic conduction sheet instead of a rigid connector. The sheet's flexibility allows it to bend and deform, accommodating position misalignments and thermal expansion between the battery and main control board while maintaining reliable electrical connection

Inventive Principle:

Principle #30Flexible shells and thin films

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

This solution decreases material costs and increases manufacturing efficiency by enabling automated assembly and ensuring reliable electrical connections through the use of an elastic conduction sheet in the battery module, which is then integrated into atomizers.

Implementation Method 1

The battery is electrically connected to the main control board by the elastic conduction sheet

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

The elastic conduction sheet has elasticity. Two ends of the elastic conduction sheet are capable of being elastically deformed

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20240049785A1Battery module and atomizer

Publication Date: 2024.02.15 LUXSHARE PRECISION IND SHENZHEN

AI summary

A battery module includes a battery, a main control board, and an elastic conduction sheet. The elastic conduction sheet has elasticity. The battery is electrically connected to the main control board by the elastic conduction sheet. One end of the elastic conduction sheet is welded to the battery and another end of the elastic conduction sheet is welded to the main control board. An atomizer includes an atomization compartment and the preceding battery module. The battery module is connected to the atomization compartment and configured to supply power to the atomization compartment.