Snap-Lock Cell Holder Trays for Safe Battery Pack Assembly
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Solution Overview
Problem
The challenge lies in safely and efficiently assembling and mechanically retaining battery cells in a battery pack, as incorrect assembly or loose cells can lead to electrical hazards or fires.
Innovation Solution
A cell holder system that uses a frame, intermediate tray, and top tray with snap-fit mechanisms to securely hold cells without traditional screws or connectors, allowing for easy assembly with minimal force and reduced risk of cell damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional screws or connectors are used to secure cells, then mechanical restraint is achieved, but the risk of electrical shock or fire increases due to loose connections
Solution Approach 1:
The patent removes traditional screws and connectors from the cell securing mechanism, extracting the harmful elements that cause electrical hazards while retaining the essential function of mechanical restraint through the tray structure itself
Solution Approach 2:
The tray assembly acts as an intermediary structure between the cells and the frame, providing mechanical restraint through integrated features rather than separate fastening components, thereby eliminating loose connection risks
2Reliability
If cells are pressed into place during assembly, then mechanical retention is achieved, but cell damage risk increases
Solution Approach 1:
The tray is designed with pre-formed recesses and locating features that guide cells into their correct positions during assembly, eliminating the need for forceful pressing while ensuring proper mechanical retention
Solution Approach 2:
The tray structure incorporates localized recesses and locating features at specific positions to accommodate and secure cell portions, providing targeted mechanical retention without requiring overall compression or pressing forces
3Reliability
If a secure cell holding mechanism is implemented, then electrical safety is improved, but assembly complexity increases
Solution Approach 1:
The patent combines multiple functions into the tray assembly structure itself - mechanical restraint, cell positioning, and electrical isolation are all integrated into the single tray component, eliminating the need for separate screws, connectors, and positioning elements
Solution Approach 2:
The tray assembly serves multiple functions simultaneously: it provides mechanical restraint for cells, positions cells through integrated locating features, and contributes to electrical isolation, thereby achieving enhanced safety without proportionally increasing structural complexity
Data Source
AI summary
A cell holder made up of a top tray, an intermediate tray and a frame. Cells are placed with minimal force in the frame to stand proud of it. The intermediate tray is placed over the projecting tops of the cells and serves to locate the cells. A busbar in the intermediate tray is connected to one set of terminals. A top tray is placed over the intermediate tray and snap-locked through the intermediate tray to the frame. The snap-lock distance is short. A busbar in the top tray is connected to the other set of terminals. The top tray shields the first busbar. Vents may be included to allow for the escape of hot cell gases in the event of failure.