Integrated Battery Pack Bracket for Tool-Free Cooling And Busbar Mounting
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Solution Overview
Problem
Existing battery pack designs face challenges in simplifying the installation of cooling and electrical components, often requiring tools and fasteners, which can lead to short circuits and complex assembly processes.
Innovation Solution
The introduction of integrated brackets that combine multiple components into a single design, featuring connection points for fluid coupling with cooling components and electrical busbars, allowing for tool-free installation by aligning end portions with structural members and using locating features for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional separate components with tools and fasteners are used for installation, then secure connection is achieved, but device complexity and installation difficulty increase
Solution Approach 1:
The bracket integrates multiple separate components (structural support, cooling line mounting, electrical component mounting) into a single unified component. This merging eliminates the need for separate fasteners and tools, allowing installation through simple alignment and engagement while maintaining secure connections for all functions.
Solution Approach 2:
The bracket serves multiple functions simultaneously: providing structural support between battery modules, mounting cooling lines, and securing electrical components like busbars. This multi-functionality reduces the overall number of components needed and simplifies the assembly process while ensuring all connections are secure.
2Reliability
If tools and fasteners are used for assembly, then reliable connection is achieved, but risk of short circuits increases
Solution Approach 1:
The design extracts and eliminates fasteners and tools from the assembly process. The bracket uses integrated features such as recesses, protrusions, and snap-fit mechanisms that enable tool-free assembly, thereby removing the sources of potential short circuits associated with metallic fasteners and assembly tools while maintaining connection reliability.
Solution Approach 2:
The bracket incorporates self-aligning and self-securing features that enable automatic positioning and locking of components without external tools. The integrated design allows components to self-align through geometric constraints and self-secure through friction-fit or snap-fit mechanisms, eliminating the need for tools that could cause short circuits.
3Productivity
If multiple separate components are used, then functional versatility is achieved, but installation time and process complexity increase
Solution Approach 1:
Multiple separate components (structural brackets, cooling line holders, electrical component mounts) are merged into a single integrated bracket assembly. This reduces the number of individual parts to be handled and installed, significantly speeding up the assembly process while maintaining all necessary functional capabilities.
Solution Approach 2:
The integrated bracket is designed to perform multiple functions simultaneously - structural support, thermal management integration, and electrical connection support. This multi-functionality eliminates the need for multiple separate components, reducing assembly steps and increasing productivity without compromising functional versatility.
Data Source
AI summary
An apparatus can include a member a member to extend between a first structural member and a second structural member. The apparatus can include at least one connection point integrated with the member. The at least one connection point can be configured to facilitate a fluid coupling between a cooling line and a cooling component. The apparatus can include at least one end portion of the member. The at least one end portion can be configured to interface with a seat of at least one of the first structural member and the second structural member.