Magnetic Locking Battery Pack Assembly Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery pack assembly methods are time-consuming and costly, and existing solutions for disconnecting and shunting faulty accumulators in high-voltage battery packs are complex and lack efficient magnetic locking/unlocking mechanisms for safe and continuous operation.
Innovation Solution
A method involving a honeycomb structure with magnetic levitation and magnetic locking/unlocking mechanisms using permanent magnets and coils for efficient assembly and disconnection of battery packs, allowing for magnetic levitation and mechanical/electrical connection/disconnection of accumulators, and a BMS-controlled magnetic switching system for safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mechanical assembly methods are used to connect battery accumulators to busbars, then the connection is reliable and stable, but the assembly time is long and production cost is high
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (screws, clips, or welding) with a magnetic field-based connection system. Permanent magnets integrated into the busbar assembly generate magnetic attraction forces that securely hold the battery accumulators in place, eliminating the need for mechanical fasteners and significantly reducing assembly time while maintaining connection reliability.
Solution Approach 2:
The magnetic connection system is designed to be self-aligning and self-securing. The magnetic field automatically guides the battery accumulators into the correct position and maintains secure connection without requiring external fastening operations or complex assembly procedures, thereby improving productivity and reducing labor costs.
2Ease of operation
If magnetic locking mechanisms are added to enable quick disconnection of faulty accumulators, then the ease of operation improves, but the device complexity increases
Solution Approach 1:
The patent implements a dynamic magnetic control system where the magnetic field strength can be adjusted in real-time. By controlling the current supplied to electromagnetic coils, the system can switch between strong magnetic attraction (for secure connection) and weak or zero magnetic field (for easy disconnection), enabling quick removal of faulty accumulators without manual force or complex mechanical release mechanisms.
Solution Approach 2:
The magnetic locking mechanism serves multiple functions: it provides secure mechanical retention, enables electrical connection, and allows for controlled disconnection. The same electromagnetic system that creates the magnetic field for attraction can also be used to actuate electrical contacts or switches, reducing the need for separate control mechanisms and thereby limiting the increase in device complexity.
3Productivity
If magnetic fields are used for connection and disconnection control, then the productivity increases and operation ease improves, but the energy consumption increases
Solution Approach 1:
The system uses permanent magnets to establish the baseline magnetic field required for connection, eliminating the need for continuous electromagnetic coil activation during normal operation. The coils are only energized temporarily during connection or disconnection events, significantly reducing overall energy consumption while maintaining high productivity benefits from the magnetic system.
Solution Approach 2:
The electromagnetic coils are activated in periodic pulses only when connection or disconnection is required, rather than continuously. This pulsed operation mode minimizes energy consumption while still providing the productivity and operational ease benefits of magnetic control, as the system returns to a low-energy permanent magnet-only state during normal 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
This approach reduces assembly time and cost, ensures safe and continuous operation of battery packs by enabling efficient magnetic connection and disconnection of accumulators, and effectively manages thermal runaway and electrical disconnection in high-voltage systems.
Implementation Method 1
a magnetic lock comprising a permanent magnet and an electrically conductive wire wound forming a coil intended to generate a magnetic field parallel to the magnetic field of the permanent magnet
Implementation Method 2
the magnetic force of attraction of the permanent magnet of the output terminal on the closing plate
Implementation Method 3
an electrically conductive wire wound forming a coil intended to generate a magnetic field parallel to the magnetic field of the permanent magnet
Data Source
Figure 1~5
Figure 6A~6B
Figure 7A~8A
AI summary
The invention essentially consists of a battery pack assembly (P) by inserting the accumulators (Al, A2...) into a honeycomb structure (11), with magnetic levitation and then the application of a magnetic field allowing the mechanical and electrical connection of the accumulators by magnetic locking.