Magnetic Battery Interconnects for Vibration Resistance
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Solution Overview
Problem
High-power batteries face issues with contact resistance leading to overheating, reliability problems due to vibration and shock, and high dismantling costs, particularly in batteries with numerous elements exposed to mechanical stress.
Innovation Solution
An interconnecting device using a conductive strip with a stamped relief for a permanent magnet to create a magnetic contact with battery terminals, eliminating air gaps and providing a reliable, vibration-proof connection with reduced weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If spot welding is used to reduce contact resistance, then contact resistance decreases, but reliability deteriorates due to sensitivity to vibrations and shocks
Solution Approach 1:
The patent replaces the mechanical welding system with a magnetic field-based system. Permanent magnets mounted on the interconnection conductor create magnetic attraction forces that press the conductor against battery terminals, eliminating the need for mechanical welding while achieving both low contact resistance and vibration resistance through non-contact magnetic force application.
Solution Approach 2:
The patent changes the fundamental parameter of contact maintenance from mechanical bonding (welding) to magnetic attraction. By utilizing magnetic field strength as the controlling parameter instead of mechanical bond strength, the system achieves both low electrical resistance and high mechanical reliability under vibration and shock conditions.
2Loss of energy
If spot welding is used to reduce contact resistance, then contact resistance decreases, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex welding operations with simple magnetic mounting. Permanent magnets are attached to the interconnection conductor using conventional mounting techniques, eliminating the need for specialized welding equipment and processes, thereby simplifying manufacturing while achieving low contact resistance.
3Loss of energy
If spot welding is used to reduce contact resistance, then contact resistance decreases, but dismantling cost increases
Solution Approach 1:
The patent replaces permanent welding bonds with magnetic attachments that can be easily separated. The magnets can be detached from the battery terminals without specialized equipment or processes, dramatically reducing dismantling costs and facilitating battery recycling and repair operations.
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 solution achieves low contact resistance, enhanced reliability against vibrations, and reduced weight and manufacturing costs, ensuring efficient energy transfer and prolonged battery life.
Implementation Method 1
au moins un aimant permanent associé à la zone de contact et configuré pour une application de la zone de contact sur un terminal dʼun élément de batterie par interaction magnétique avec lʼélément de batterie
Data Source
AI summary
A device for interconnecting battery elements has at least one electrically conductive strip with at least one contact area for a battery element, and at least one permanent magnet, which magnet is associated with the contact area and configured to apply the contact area to a terminal of a battery element by magnetic interaction with the battery element. The contact area of the strip has a stamped relief in the strip, the stamped relief forming a receptacle for a magnet. The magnet is housed within the receptacle for a magnet. Also disclosed is a battery of accumulators provided with the interconnection device. It is applicable to batteries for supplying power to handheld power tools, in particular.