Weldingless Cylindrical Battery Pack Mechanical Connection
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Solution Overview
Problem
Conventional battery packs face challenges due to the weight, volume, and complexity of rechargeable batteries, which can lead to safety issues and environmental concerns, particularly with large single batteries, and the difficulty in manufacturing and recycling due to welding requirements.
Innovation Solution
A weldingless cylindrical battery pack design that uses lid bodies, screwing elements, and elastic pieces to connect cylindrical batteries without welding, simplifying the manufacturing process and allowing for easy replacement of broken batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are welded to conductive bodies for electronic connection, then electrical connectivity is achieved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing system. Conductive plates are pressed against battery terminals using pressing devices, eliminating welding operations while achieving reliable electrical connection. This substitution simplifies the manufacturing process and reduces complexity.
Solution Approach 2:
The patent introduces conductive plates as intermediary elements between batteries and conductive bodies. These plates facilitate electrical connection through mechanical contact rather than direct welding, serving as a mediator that simplifies the connection process and enables easier assembly and disassembly.
2Reliability
If batteries are welded to conductive bodies, then electrical connection is established, but disassembly and battery replacement become difficult
Solution Approach 1:
The patent replaces irreversible welding with reversible mechanical pressing. The conductive plates can be pressed onto battery terminals and easily removed when needed, allowing for simple battery replacement without complex welding solutions or specialized equipment.
Solution Approach 2:
The connection system transitions from a static welded joint to a dynamic mechanical connection that can be easily assembled and disassembled. The pressing mechanism allows the connection to be established and released multiple times, providing flexibility for maintenance and battery replacement.
3Volume of stationary object
If a large single rechargeable battery is used, then battery pack volume is reduced, but safety decreases and explosion risk increases
Solution Approach 1:
The patent divides the battery pack into multiple smaller cylindrical batteries arranged in parallel, rather than using a single large battery. This segmentation reduces the volume and potential risk of each individual battery cell while maintaining the overall energy capacity of the pack.
Solution Approach 2:
The patent combines multiple small batteries in parallel configuration to achieve the desired total capacity. By merging multiple smaller units, the system maintains the volume efficiency of compact design while improving safety through distribution of energy across multiple smaller cells.
4Reliability
If multiple small rechargeable batteries are used, then safety is improved, but total weight and volume increase
Solution Approach 1:
The patent combines multiple small batteries in parallel configuration, where the total capacity equals the sum of individual batteries. This approach achieves the safety benefits of smaller cells while optimizing the overall weight and volume through efficient spatial arrangement and parallel connection architecture.
Data Source
AI summary
A weldingless cylindrical battery pack device has a first lid body, a second lid body, multiple cylindrical batteries, multiple screwing elements, a first elastic piece, and a second elastic piece. The cylindrical batteries are mounted between the first lid body and the second lid body. The first lid body and the second lid body are screwed together by the screwing elements. Further, the first elastic piece is electronically connected to positive electrodes of the cylindrical batteries, and the second elastic piece is electronically connected to negative electrodes of the cylindrical batteries. The cylindrical batteries do not need to be welded, and the weldingless cylindrical battery pack device may be easily and quickly manufactured.