Battery Array Plate Interlocking Mechanism
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Solution Overview
Problem
There is a need for space-efficient battery pack designs for electrified vehicles, as conventional designs often have limited space and require complex assembly due to the use of multiple battery assemblies and enclosures.
Innovation Solution
The battery pack incorporates an array plate with engagement features that interlock with corresponding features on adjacent array plates or enclosures, eliminating the need for conventional bolting mechanisms and allowing for a compact, modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional battery pack designs are used with multiple battery assemblies and enclosures, then the battery pack can accommodate multiple battery cells, but the volume and complexity increase
Solution Approach 1:
The patent merges the functions of multiple battery assemblies and enclosures into a single integrated battery assembly with an integrated enclosure. The engagement features allow multiple battery cells to be secured within one unified structure, eliminating the need for separate enclosures for each assembly and reducing overall pack volume.
Solution Approach 2:
The integrated enclosure serves multiple functions: it houses the battery cells, provides structural support, and incorporates engagement features for securing adjacent battery assemblies. This multi-functional design reduces the number of separate components needed, thereby reducing volume while accommodating multiple cells.
2Ease of manufacture
If conventional enclosures with multiple battery assemblies are used, then the battery pack can be assembled, but the assembly process becomes complex
Solution Approach 1:
The battery pack is divided into modular battery assemblies, each with its own integrated enclosure and engagement features. This segmentation allows for standardized, pre-assembled units that are easier to manufacture and assemble, reducing overall packaging complexity while maintaining ease of manufacture.
Solution Approach 2:
The engagement features are designed to automatically interlock adjacent battery assemblies without requiring additional fastening mechanisms or complex assembly steps. The protrusion and recess features self-align and secure the assemblies together, simplifying the assembly process and reducing manufacturing complexity.
3Device complexity
If engagement features are added to array plates, then the assembly is simplified and complexity is reduced, but the array plate design becomes more complex
Solution Approach 1:
The engagement features use asymmetric protrusion and recess geometries that are simple in form but effective in function. The protrusion extends from one array plate while the corresponding recess is formed in the adjacent plate, creating a simple yet effective interlocking mechanism that reduces overall assembly complexity without significantly complicating the array plate design.
Data Source
AI summary
A battery pack according to an exemplary aspect of the present disclosure includes, among other things, an array plate including a first engagement feature configured to engage a second engagement feature when the first engagement feature is positioned proximate another structure equipped with the second engagement feature.