LDS Battery Holder Assembly for Weld-Free Vaporizer Cell Connection
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Solution Overview
Problem
The assembly operations of battery cells in electronic vaporization devices are complex and require manual welding, making them difficult to assemble safely and reliably for automatic production.
Innovation Solution
A holder assembly with a conductive structure formed using the laser direct structuring (LDS) process, which integrates with the holder to facilitate automatic assembly of battery cells by forming an integral structure, enabling efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual welding is used to assemble battery cells, then reliable electrical connections can be achieved, but the assembly process becomes complex and difficult to automate
Solution Approach 1:
The conductive structure is integrated directly into the holder body, merging the holder and conductive elements into a single unified component. This eliminates the need for separate welding operations while maintaining reliable electrical connections, thereby simplifying the assembly process and enabling automation.
Solution Approach 2:
The patent replaces the mechanical welding process with a molded integral structure. The conductive pathways are formed as inherent features of the holder during molding, substituting the complex mechanical welding system with a simpler molding-based solution that achieves the same electrical connection reliability.
2Reliability
If manual welding operations are performed, then safe and reliable battery cell assembly can be achieved, but productivity and assembly speed are reduced
Solution Approach 1:
By combining the holder and conductive structures into a single integral component, the patent eliminates multiple manual welding steps. The battery cell can be directly assembled into the molded holder, significantly improving assembly speed and productivity while maintaining safety and reliability through the precision of the molded integral structure.
3Reliability
If separate conductive components are used, then electrical connections can be established, but the structure becomes complex and assembly time increases
Solution Approach 1:
The conductive structures are merged into the holder as an integral molded feature, eliminating the need for separate conductive components. This reduces assembly time by allowing the battery cell to be directly installed into the holder without additional steps to attach separate conductive elements, while maintaining electrical connection reliability through the precision-molded integral structure.
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 LDS-formed conductive structure simplifies and automates the assembly of battery cells, enhancing the efficiency and reliability of the assembly process while ensuring safe and reliable connections.
Implementation Method 1
the conductive structure is formed on the holder using a laser direct structuring (LDS) process and forms an integral structure with the holder
Data Source
AI summary
A holder assembly includes: a holder for accommodating a battery cell; and a conductive structure arranged on the holder. The conductive structure is formed on the holder using a laser direct structuring (LDS) process and forms an integral structure with the holder. In an embodiment, the holder has a bottom wall, and the conductive structure is at least partially formed on an inner surface of the bottom wall.