Movable Battery Box Frame for Fastener-Free Assembly
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Solution Overview
Problem
The complexity and time required in manufacturing a battery box assembly, especially in space-constrained scenarios, due to the need for specialized tools and tedious assembly steps, are exacerbated by the dense configuration of parts.
Innovation Solution
A battery box assembly utilizing movable frame members with pegs and isolators that interface with the vehicle frame, allowing for lateral movement and retention of parts, which are then fixed in place by the battery, eliminating the need for fasteners and specialized tools, and a cover that mechanically couples to retain the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a dense configuration of parts is used in the battery box assembly, then space utilization is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The movable frame member integrates multiple functions: it defines the battery cavity, provides lateral movement capability, and incorporates interfaces with the vehicle frame. This consolidation of functions into a single component achieves dense space utilization without proportionally increasing assembly complexity
Solution Approach 2:
The battery itself serves as a retaining mechanism for the movable frame member. When the battery is installed in the cavity, it automatically restricts lateral movement of the movable frame member, eliminating the need for separate fasteners or retaining mechanisms
2Volume of moving object
If a dense configuration of parts is used in the battery box assembly, then space utilization is improved, but manufacturing time increases
Solution Approach 1:
The design removes fasteners and specialized retaining mechanisms from the assembly process. The battery box assembly can be manufactured without these additional components, reducing the number of assembly steps and specialized tools required while maintaining dense space utilization
Solution Approach 2:
The battery serves a dual purpose: it is both the energy source and the retaining mechanism. Its installation automatically secures the movable frame member, eliminating separate fastening operations and reducing overall assembly time
3Device complexity
If a less dense configuration is used to avoid complexity, then device complexity is reduced, but space utilization deteriorates
Solution Approach 1:
The movable frame member is designed to move laterally during assembly and is then restricted by the battery installation. This dynamic approach allows for a compact initial configuration that achieves dense space utilization without requiring complex permanent retaining structures
Data Source
AI summary
Aspects of the present disclosure relate to a battery support for a battery. As an example, the battery support comprises a first frame, a second frame spaced apart from the first frame to define a cavity, and a movable frame member positionable in the cavity. The movable frame member comprises a first interface configured to interface with a corresponding second interface of the first frame when the movable frame member is moved in a first direction toward the first frame. The movable frame member cooperates with the second frame to define a battery cavity sized to receive the battery and to restrict movement of the movable frame member in a second direction opposite the first direction when the battery is received by the battery cavity.