Reversible Battery Pack Assembly Using Spring-Loaded Clips
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Solution Overview
Problem
Current battery pack assembly processes are complex and time-consuming due to irreversible welding of interconnect boards and require multiple components for cooling, making them difficult to assemble and disassemble safely and efficiently.
Innovation Solution
A reversible electrical connection system using frames with embedded or external buss lines and spring-loaded metal clips allows for easy assembly and disassembly, integrating cooling and electrical features to support scalable and cost-effective battery packs with improved safety and reduced component complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect interconnect boards to battery cells and frames, then electrical connection reliability is improved, but assembly complexity and time increase
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical connection system using interconnect boards that are plastic-welded to frames and spring-loaded clips that apply mechanical pressure to create reversible electrical connections between battery cells. This substitution eliminates the need for secondary welding processes while maintaining electrical connection reliability.
Solution Approach 2:
The patent divides the battery pack into modular segments where interconnect boards serve as separate components that can be independently assembled and disconnected. The spring-loaded clips further segment the connection system, allowing individual cell connections to be made or broken without affecting the entire battery pack structure.
2Reliability
If welding is used to connect interconnect boards to frames, then electrical connection stability is improved, but ease of disassembly deteriorates
Solution Approach 1:
The patent introduces dynamic, reversible connections through spring-loaded clips that can be easily engaged and disengaged. The springs provide continuous contact pressure for stable electrical connection during operation, while allowing quick release when disassembly is needed, transforming a static permanent connection into a dynamic reversible one.
Solution Approach 2:
The patent enables easy recovery and reuse of interconnect boards and other components through the reversible connection system. Components that would traditionally be permanently welded and discarded or difficult to recover can now be easily separated and reused in subsequent assemblies.
3Temperature
If multiple components are used for cooling and expansion control, then thermal management effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the interconnect boards and frames. These components simultaneously provide structural support, electrical connection pathways, cooling channels for thermal management, and expansion accommodation spaces. This consolidation reduces the total number of separate components while maintaining all necessary functions.
Solution Approach 2:
The interconnect boards and frames are designed as multi-functional components that perform multiple roles: mechanical support, electrical conduction, thermal management through integrated cooling channels, and accommodation of cell expansion. This universality eliminates the need for separate dedicated components for each function.
4Reliability
If coolant seals are used to maintain cleanliness, then cooling system reliability is improved, but assembly complexity increases
Solution Approach 1:
The patent designs the cooling system with self-sealing features where the interconnect boards and frames create inherent seals through their structural design and material properties. The system maintains coolant containment through its geometric configuration and material characteristics rather than requiring separate complex sealing components and assembly procedures.
Data Source
AI summary
A reversibly connected battery pack is provided. The reversibly connected battery pack includes a pair of end frames, at least one frame, a plurality of battery cells, and at least one power connector. One end frame has a positive terminal, and the other has a negative terminal. The frame(s) is positioned between the pair of end frames. Each of the plurality of battery cells has a positive tab and a negative tab. The positive tab of one of the plurality of battery cells is electrically connected to the positive terminal in the end frame, and the negative tab of another one of the plurality of battery cells is electrically connected to the negative terminal in the end frame. The plurality of battery cells are positioned in the frame(s) and the end frames. The plurality of battery cells and the positive and negative tabs are supported by the frame and the pair of end frames. There is at least one power connector electrically connecting the negative tab of one battery cell with the positive tab of an adjacent battery cell.