Battery Assembly Clip for Weld-Free Collar Retention
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Solution Overview
Problem
The existing methods for securing high voltage batteries to vehicle components require welding, which is costly, space-intensive, and can cause heat distortions, while also making the installation permanent and difficult to service.
Innovation Solution
A clip system that retains a collar in position on a battery assembly, using a mounting portion with retaining studs for secure engagement with the battery assembly and a gripping portion that resiliently deflects to securely hold the collar, thereby maintaining a defined spacing between the battery and the vehicle component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to secure the collar to the battery assembly, then the collar is firmly fixed in position, but the equipment becomes expensive, bulky, and causes heat distortions
Solution Approach 1:
The patent replaces the welding process with a mechanical retention system consisting of a clip and collar assembly. The clip engages with the battery assembly through friction and geometric interlocking, while the collar provides a standardized interface for mechanical attachment. This substitution eliminates the need for welding equipment and associated heat processes, directly resolving the contradiction between fixation strength and equipment complexity.
2Stability of the object's composition
If welding is used to secure the collar, then the collar is permanently fixed, but disassembly and servicing become difficult
Solution Approach 1:
The patent employs a dynamic retention system where the clip can be easily inserted and removed from the battery assembly. The collar features a through-hole that accepts retention pins or clips, allowing for quick assembly and disassembly. This dynamic design maintains stable positioning during operation while enabling easy servicing when needed, resolving the contradiction between position stability and ease of repair.
3Strength
If welding equipment is used, then secure attachment is achieved, but the equipment is expensive and space-intensive
Solution Approach 1:
The patent utilizes simple, inexpensive mechanical components - a clip made from sheet material and a collar with a through-hole - that can be manufactured at low cost using basic forming and machining operations. These components replace expensive welding equipment and consumables, achieving secure attachment through mechanical means while dramatically reducing manufacturing costs and space requirements.
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
The clip system allows for easy assembly and disassembly of the battery assembly, eliminating the need for welding and associated costs, while maintaining a consistent spacing and facilitating servicing operations.
Implementation Method 1
a gripping portion configured to resiliently deflect as urged into engagement with an outer engagement surface of the collar to securely retain the collar therewithin
Implementation Method 2
a resiliently deflectable finger, that is adapted to deflect on insertion into the hole for frictional engagement with an interior surface of the hole
Data Source
AI summary
A clip for retaining a collar in position on a surface of a battery assembly during assembly of the battery assembly to a vehicle body component, wherein the collar is retained between the surface of the battery assembly and the vehicle body component when assembled to maintain a defined spacing therebetween. The clip comprises a mounting portion comprising a retaining stud releasably engageable with a corresponding hole in the surface of the battery assembly for retention of the clip on said surface. The clip also comprises a gripping portion configured to resiliently deflect as urged into engagement with an outer engagement surface of the collar to securely retain the collar therewithin.