Magnetic Battery Pack Fixing for Weld-Free Cell Replacement
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Solution Overview
Problem
Existing medium and large-sized battery packs require complex welding processes to connect and fix battery cells, making it difficult to replace damaged cells and potentially affecting performance and safety.
Innovation Solution
A battery pack design using a magnetic fixing unit with first and second members that attach to battery cells and the pack housing via magnetic forces, allowing easy assembly and disassembly without welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect and fix battery cells, then structural stability and electrical connection are achieved, but the process becomes extremely complicated and time-consuming
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a magnetic fixing system. Magnets are attached to the battery cells and the housing to provide both structural fixation and electrical connection through conductive materials, eliminating the need for welding operations while maintaining structural stability and electrical connectivity.
Solution Approach 2:
The magnetic fixing structure serves multiple functions simultaneously: it provides structural stability by fixing battery cells in position, enables electrical connection through conductive magnetic components, and allows for easy assembly and disassembly. This multi-functional design replaces the separate welding processes for both mechanical and electrical connections.
2Reliability
If welding is used to fix battery cells, then structural stability is achieved, but damaged cells become hard to separate and replace
Solution Approach 1:
The magnetic fixing system provides dynamic adjustability - the magnetic force can be easily overcome to remove cells when needed, yet maintains sufficient holding force for stable operation. This allows battery cells to be firmly fixed during use but easily removed and replaced when damaged, unlike permanent welding connections.
Solution Approach 2:
By replacing the permanent welding connection with a magnetic connection system, the patent enables easy separation and replacement of battery cells. The magnetic force can be easily overcome by applying minimal force to remove cells, while maintaining stable fixation during normal operation, thus improving repairability without sacrificing structural stability.
3Reliability
If welding is used to connect battery cells, then electrical connection is achieved, but deformation of battery cell occurs due to welding intensity
Solution Approach 1:
The patent replaces the welding process (which generates heat causing deformation) with a magnetic fixing system. The magnetic components provide electrical connection through conductive materials without generating thermal energy, thereby eliminating the harmful thermal effects that cause battery cell deformation while maintaining reliable electrical connection.
4Reliability
If welding process is used, then battery cells are securely connected, but manufacturing time and cost increase
Solution Approach 1:
The magnetic components can be pre-attached to battery cells and the housing separately, then quickly assembled together through magnetic attraction without requiring complex welding operations. This preliminary preparation and simple assembly process significantly reduces manufacturing time and increases production efficiency while maintaining secure connections.
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
Facilitates quick and secure attachment of battery cells, simplifies manufacturing, reduces costs, and enables easy replacement of damaged cells, enhancing safety and performance.
Implementation Method 1
a fixing unit disposed in the battery pack housing to fix a position of the plurality of battery cells by using a magnetic force
Data Source
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AI summary
Disclosed are a battery pack including a battery pack housing, a plurality of battery cells disposed in the battery pack housing, and a fixing unit disposed in the battery pack housing to fix a position of the plurality of battery cells by using a magnetic force and a manufacturing method thereof, and a method for placing the battery cell of the battery pack applied thereto, and more particularly, a battery pack capable of easily fixing a plurality of battery cells in a battery pack housing and a manufacturing method thereof, and a method for placing a battery cell of the battery pack.