Battery Module Case Alignment for Multi-Stage Plate Assembly

Solution Overview

Problem

The assembly of a case to a plate member in battery modules is inefficient, particularly in multi-stage configurations, due to the complexity and difficulty in aligning and fixing components.

Innovation Solution

A battery module design featuring a case with an engagement protrusion and a guide protrusion, where the guide protrusion is longer than the engagement protrusion, facilitates easy alignment and fixation by guiding the engagement protrusion into a lock hole, improving assembly efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a case is fixed to a plate member in a multi-stage battery module configuration, then the structural stability is improved, but the assembly complexity and difficulty increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidassembly complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The fixing mechanism is segmented into distinct functional components: a guide protrusion for alignment, an engagement protrusion for securing, and corresponding guide holes and lock holes in the plate member. This segmentation allows each component to perform its specific function independently, simplifying the overall assembly process while maintaining structural stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The guide protrusion performs a preliminary alignment action by fitting into the guide hole before the engagement protrusion secures the case to the plate member. This preliminary positioning action simplifies the assembly process by pre-establishing the correct orientation and position, reducing the complexity of the subsequent fixing operation.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If multiple fixing points are provided on the plate member, then the reliability of fixation is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvefixation reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fixing mechanism is segmented into distinct functional components: a guide protrusion for alignment, an engagement protrusion for securing, and corresponding guide holes and lock holes in the plate member. This segmentation allows each component to perform its specific function independently, simplifying the overall assembly process while maintaining structural stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plate member integrates multiple functions into a single component: it provides structural support, incorporates guide holes for alignment, and includes lock holes for securing the case. This multi-functionality reduces the number of separate parts needed, simplifying manufacturing while ensuring reliable fixation through multiple engagement points.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If the case is designed with engagement and guide protrusions, then the ease of assembly is improved, but the device complexity increases

Engineering Contradiction:

Improveease of assemblyVSAvoidcase structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The guide protrusion performs a preliminary alignment action by fitting into the guide hole before the engagement protrusion secures the case to the plate member. This preliminary positioning action simplifies the assembly process by pre-establishing the correct orientation and position, reducing the complexity of the subsequent fixing operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The guide protrusion and engagement protrusion are designed to automatically align and engage with their corresponding holes in the plate member without requiring additional tools or complex positioning mechanisms. The case essentially assembles itself through these self-guiding features, improving ease of assembly while keeping the structural complexity manageable.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20260031464A1Battery module

Publication Date: 2026.01.29 YAZAKI CORP

AI summary

A battery module includes a case that accommodates a wiring member; and a plate member that is disposed at an end portion of each of a plurality of battery cells and supports the case, in which a lock hole and a guide hole are provided side by side on a side surface of the plate member facing the case, the case includes a main body that accommodates the wiring member, and an engagement protrusion and a guide protrusion protruding from the main body, the engagement protrusion is inserted into the lock hole to engage with the plate member, and the guide protrusion is inserted into the guide hole to guide the engagement protrusion to the lock hole, and is longer than the engagement protrusion.