Snap-Fit Battery Cell Assembly for Compact Modular Packs
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Solution Overview
Problem
Existing battery technologies face challenges in optimizing production efficiency, miniaturization, and ensuring reliable connections between battery cells, particularly in cylindrical cells, due to issues with alignment, welding, and explosion-proof valve placement.
Innovation Solution
A snap-fit connection mechanism using first and second snap-fit bodies on the cathode and anode ends of adjacent battery cells, limiting movement and facilitating easy adjustment of cell numbers, with a trapezoidal strip block and dovetail-shaped groove design for reliable electrical contact and simplified welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are connected using electrical connectors, then connection reliability is maintained, but production efficiency decreases and device complexity increases
Solution Approach 1:
The patent merges the connection function into the battery cell structure itself by integrating snap-fit bodies directly onto the battery cells. This eliminates the need for separate electrical connectors, thereby reducing component count and simplifying the overall device structure while maintaining connection reliability through the integrated snap-fit mechanism.
Solution Approach 2:
The patent extracts the connection function from external electrical connectors and relocates it directly to the battery cell structure. By taking out the separate connector component and integrating its functionality into the battery cell itself, the system achieves simpler assembly and improved production efficiency without sacrificing connection reliability.
2Reliability
If battery cells are arranged with fixed positioning structures, then connection reliability improves, but manufacturing complexity increases
Solution Approach 1:
The snap-fit bodies are designed to automatically self-align and self-position when adjacent battery cells are brought together. This self-service mechanism eliminates the need for complex external positioning structures or precision alignment fixtures during manufacturing, thereby reducing manufacturing complexity while ensuring reliable connections through automatic geometric constraint.
3Quantity of substance
If the number of battery cells is increased for higher capacity, then energy storage improves, but assembly complexity and production time increase
Solution Approach 1:
The patent segments the battery system into modular battery cells, each equipped with standardized snap-fit connection bodies. This segmentation allows cells to be independently manufactured and then rapidly assembled into larger battery packs by simply connecting the snap-fit bodies, thereby enabling easy scaling of cell number without proportionally increasing assembly complexity or production time.
4Volume of moving object
If terminal posts are positioned closer for compact design, then miniaturization improves, but connection reliability deteriorates due to gap formation
Solution Approach 1:
The snap-fit bodies incorporate curved or tapered geometric features that enable progressive engagement as adjacent battery cells are brought together. This curved geometry ensures continuous contact and progressive alignment, eliminating gap formation even when terminal posts are positioned closely, thereby maintaining connection reliability while enabling compact battery design.
Data Source
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AI summary
The present application provides a battery, a power consuming device, and a method for manufacturing a battery. The battery according to an embodiment of the present application includes two or more battery cells arranged in a first direction, where one of a cathode and an anode of each of the battery cells is configured with a first snap-fit body, the other one of the cathode and the anode of each of the battery cells is configured with a second snap-fit body, the first snap-fit body of one of any two adjacent battery cells is snap-fit to the second snap-fit body of the other one of the any two adjacent battery cells, and movement of the battery cells connected by snap-fitting the first snap-fit body to the second snap-fit body in the first direction is limited. Since the battery cells can be directly connected by snap-fitting the snap-fit bodies without a traditional electrical connector, assembly efficiency is high, miniaturization and lightweight of the battery are facilitated, and the number of the battery cells connected can be easily adjusted according to actual usage.