Battery Array Frame Design for Electrified Vehicle Stability
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Solution Overview
Problem
Electrified vehicle battery arrays face challenges in securing and stabilizing multiple battery cells within the array frame, ensuring efficient heat management, and facilitating easy assembly and handling.
Innovation Solution
The battery array frame design includes a longitudinal frame body with top and bottom surfaces, frame arms, alternating rigid and flexible snap arms, lifting arms, recessed grooves for tension straps, and embedded thermal fins, allowing for secure stacking, heat management, and tool engagement for handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple battery cells are secured within the array frame using traditional methods, then the battery cells are held in place, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The array frame is divided into modular units with individual frame arms that can independently secure battery cells. Each frame arm acts as a separate securing element that can be independently positioned and locked, allowing for simplified assembly of large battery arrays by working with manageable sections rather than a monolithic structure.
Solution Approach 2:
The frame arms are pre-configured with retention features and positioning elements during manufacturing. The rotationally symmetric top and bottom surfaces are pre-designed with alternating patterns of rigid and flexible snap arms that automatically engage with corresponding features on adjacent frames, eliminating the need for complex assembly procedures during installation.
2Reliability
If the array frame design includes comprehensive securing features for all battery cells, then the battery cells are securely held, but the manufacturing complexity and cost increase
Solution Approach 1:
The array frame design uses universal frame arms with rotationally symmetric top and bottom surfaces that can secure battery cells in multiple orientations and positions. The alternating pattern of rigid and flexible snap arms provides multi-functional securing capabilities - rigid snap arms for primary structural support and flexible snap arms for accommodating minor misalignments and thermal expansion - all within a single frame design.
Solution Approach 2:
The frame arms incorporate flexible snap arms that can change their mechanical properties dynamically. These snap arms are designed to be rigid during normal operation to provide secure holding, but become more compliant during assembly to facilitate easy engagement. The flexibility allows the same frame design to accommodate variations in battery cell dimensions and positioning tolerances without requiring custom manufacturing for each case.
3Temperature
If the array frame includes features for heat management integration, then thermal control is improved, but the device complexity increases
Solution Approach 1:
The array frame merges structural support functions with thermal management functions into a single integrated component. The frame arms serve both as mechanical securing elements and as thermal conduction pathways. By embedding thermal management features directly into the frame structure rather than adding separate cooling systems, the design achieves effective heat dissipation while minimizing overall system complexity.
Solution Approach 2:
The frame arms are designed to perform multiple functions simultaneously: mechanical support, cell securing, and thermal conduction. The rotationally symmetric design with alternating rigid and flexible snap arms provides both structural integrity and thermal pathways to cooling plates, eliminating the need for separate dedicated cooling structures and reducing overall system complexity.
4Ease of operation
If the array frame design includes lifting arms and engagement features, then handling and installation are simplified, but the frame weight increases
Solution Approach 1:
The lifting arms and engagement features are pre-integrated into the frame structure during manufacturing, positioned at optimal locations for handling and installation. The rotationally symmetric top and bottom surfaces include pre-configured engagement features that work with standard installation tools, eliminating the need for additional heavy-duty lifting equipment and simplifying the installation process without requiring excessive frame weight.
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 design enhances the stability and assembly efficiency of battery arrays by securing battery cells, managing heat effectively, and simplifying the handling and installation process, thereby improving the overall performance and reliability of electrified vehicle battery systems.
Implementation Method 1
at least one recessed groove disposed outboard of a thermal fin embedded within the frame body
Data Source
AI summary
A battery array frame according to an exemplary aspect of the present disclosure includes, among other things, a frame body extending along a longitudinal axis and including a top surface, a bottom surface and frame arms that connect between the top surface and the bottom surface. At least one of the top surface and the bottom surface is rotationally symmetric about an axis that is transverse to the longitudinal axis.