Battery Case Beam Connection Structure for Precise Pack Assembly

A connecting piece is introduced as an intermediary component between the intermediate beam and side beams. This connecting piece includes a connecting body with a first groove and a fastening structure, serving as a mediator that enables reliable connection while maintaining structural clarity. The connecting piece resolves the contradiction by providing a specialized interface that enhances connection reliability without requiring complex direct joining mechanisms between the beams themselves.

The connection structure is segmented into distinct functional components: the intermediate beam, the side beams, and the connecting piece with its own fastening structure. This segmentation allows each component to be optimized independently - the connecting piece can be designed with specific grooves and fastening features tailored for reliable joining, while the beams maintain their primary structural functions. The segmentation resolves the contradiction by distributing connection functionality across dedicated components rather than requiring the beams themselves to incorporate complex connection features.

The connection structure employs reversible fastening mechanisms that can dynamically transition between locked and unlocked states. The fastening structure on the connecting piece includes features that enable firm fixation during operation while allowing controlled disassembly when needed. This dynamic capability resolves the contradiction by providing strong connection during battery pack operation while maintaining ease of assembly and disassembly for manufacturing and maintenance activities.

The connecting piece acts as a mediator that decouples the strength requirement from the beams themselves. The fastening structure on the connecting piece can be designed with optimized fastening features (such as threaded holes, snap-fit mechanisms, or welded joints) that provide strong connection without requiring the beams to have built-in complex fastening features. This intermediary approach allows the beams to remain simple structural elements while the connecting piece handles the strong fixation requirement in a controllable manner.

The connecting piece serves as a precision intermediary that absorbs and compensates for dimensional variations. The first groove and fastening structure on the connecting piece can be designed with built-in tolerance compensation features, such as adjustable fastening positions or self-aligning geometries. This allows the connecting piece to bridge small gaps or misalignments between beams without requiring extremely tight manufacturing tolerances on the beams themselves, thereby maintaining connection reliability while reducing overall assembly precision requirements.

The precision-critical features are extracted from the beams and concentrated in the connecting piece. Rather than requiring all beam components to have high-precision features, the design extracts the precision requirements into the dedicated connecting piece, which can be manufactured and pre-assembled with tight tolerances as a separate unit. This extraction allows the majority of the beam structure to be manufactured with more relaxed tolerances, reducing overall manufacturing complexity while maintaining connection reliability through the precision-engineered connecting piece.