Battery Cross-Member Assembly for Accurate Tab Terminal Positioning
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Solution Overview
Problem
The assembly of traction battery packs in electrified vehicles faces challenges in efficiently positioning and securing tab terminals within cross-member assemblies, which affects the structural integrity and thermal management of the battery pack.
Innovation Solution
A method involving the positioning of one or more terminals of a cell stack within a slot provided by a frame of a cross-member assembly, followed by securing a beam to the frame, which may include adhesive securing and additional securing to a thermal exchange plate, ensuring proper alignment and stability of the terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tab terminals are positioned within slots of the frame before securing beams, then manufacturing precision and alignment are improved, but assembly complexity increases
Solution Approach 1:
The patent applies preliminary action by positioning the tab terminals within the slots of the frame before securing the beams. This sequence ensures that terminals are pre-aligned and properly positioned, improving manufacturing precision while the subsequent beam securing step consolidates the structure without requiring additional positioning operations.
2Strength
If multiple securing methods (adhesive and mechanical) are used for beams, then structural integrity is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent merges multiple securing methods by combining adhesive bonding with mechanical fastening (clips or fasteners) to secure the beams to the frame. This combination ensures that the structural integrity requirements are met through dual securing mechanisms, while the processes are integrated into a streamlined assembly sequence that minimizes manual intervention.
3Temperature
If terminals are positioned before beam securing, then thermal management effectiveness is improved, but assembly time increases
Solution Approach 1:
The patent applies preliminary action by positioning the terminals in the slots before securing the beams, which enables thermal exchange plates to be properly aligned and connected to cooling channels. This preliminary positioning ensures effective thermal management is established, while the subsequent beam securing step completes the structure in a single consolidated operation, minimizing total assembly time.
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
This method ensures accurate and secure positioning of tab terminals within the battery pack, enhancing the structural integrity and thermal management of the traction battery pack, thereby improving the overall performance and reliability of electrified vehicles.
Implementation Method 1
securing a beam of the cross-member assembly to the frame after the positioning, wherein the securing includes adhesively securing the beam to the frame
Implementation Method 2
additionally securing the beam to a thermal exchange plate, the cell stack disposed on the thermal exchange plate
Data Source
AI summary
A method of assembling a battery pack includes positioning one or more terminals of a cell stack within a slot that is provided by a frame of a cross-member assembly. The method further includes securing a beam of the cross-member assembly to the frame after the positioning. The beam can be a pultruded beam that covers several slots of the frame.