Snap-Fit Battery Pack Bracket With Reinforced Manifold Mounting
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Solution Overview
Problem
Existing battery pack assembly processes are inefficient and lack structural integrity, particularly in supporting fluid manifolds for battery modules.
Innovation Solution
A multi-functional saddle bracket with a snap-fit design and overmolded reinforcement features that integrates with the battery pack frame, providing structural support and efficient mounting and alignment for coolant manifolds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery pack assembly processes are used, then manufacturing simplicity is maintained, but assembly efficiency and structural integrity deteriorate
Solution Approach 1:
The bracket integrates multiple functions into a single component: structural support, fluid manifold mounting, and alignment features are combined in one piece. This merging of functions eliminates the need for separate components and fasteners, thereby improving assembly efficiency while maintaining manufacturability through a unified injection molding process
2Reliability
If traditional mounting methods are used, then manufacturing simplicity is maintained, but structural integrity and manifold mounting reliability deteriorate
Solution Approach 1:
The bracket incorporates an aluminum insert embedded within a polymer body, creating a composite structure that combines the high strength and thermal conductivity of aluminum with the damping and molding capabilities of polymer materials. This composite construction enhances manifold mounting reliability while maintaining a relatively simple single-piece bracket design
3Strength
If simple bracket designs are used, then manufacturing ease is maintained, but structural support capability and resilience deteriorate
Solution Approach 1:
The aluminum insert provides enhanced structural support capability and load-bearing strength, while the polymer matrix allows for complex geometries and integrated features to be formed through injection molding. This composite approach achieves high strength requirements without significantly complicating the manufacturing process
Solution Approach 2:
The aluminum insert is strategically positioned within the bracket at locations requiring enhanced strength and stiffness, while other areas of the bracket maintain the simpler polymer construction. This localized reinforcement provides necessary structural support capability only where needed, optimizing the balance between strength and manufacturing ease
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
Facilitates a simplified and more efficient assembly process for battery packs while ensuring structural integrity and effective manifold mounting, enhancing the manufacturability and reliability of battery packs.
Implementation Method 1
an aluminum insert configured to transfer a load to a structural member of a frame
Implementation Method 2
one or more snap features configured to attach the bracket to the structural member of the frame using a snap fit
Implementation Method 3
one or more guide features configured to guide the multi-functional saddle bracket along the structural member
Data Source
AI summary
Aspects of the disclosure relate to a multi-functional bracket, such as for a battery pack. The disclosed bracket may allow for a simplified and more efficient assembly process for the battery pack using a plastic snap-fit main body, while providing both structural integrity for the pack using a overmolded reinforcement feature, and mounting and alignment for fluid manifolds for the battery modules.