Battery End Plate Snap-Fit Assembly for Cell Stack Compression
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Solution Overview
Problem
Current assembly methods for battery cell stacks face challenges in achieving consistent and efficient compression, often requiring cumbersome pre-compression and fixation techniques like welding or bolting, which are time-consuming and prone to errors.
Innovation Solution
A battery system with a cell stack frame featuring interlocking elements on the end plate and frame walls that establish a snap-fit mechanism, allowing for easy assembly and ensuring desired compression without pre-compression, using cantilever snap-fit elements and receptacles for secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-compression is applied to the cell stack before insertion, then the cell stack can be inserted into the cavity, but the assembly process becomes cumbersome and complicated
Solution Approach 1:
The cell stack is pre-compressed using a compression device before insertion into the cavity. This preliminary compression action enables the cell stack to be inserted into the cavity without requiring complex pre-compression mechanisms during final assembly, as the compression is performed in advance using specialized equipment.
Solution Approach 2:
A compression device acts as an intermediary tool to compress the cell stack before insertion. This intermediary device handles the complex compression task separately, allowing the final assembly process to be simpler and less cumbersome.
2Reliability
If the cell stack is over-compressed to enable damage-free insertion, then the cell stack can be inserted without damage, but most of the pre-tension is lost when the insertion clamp is released
Solution Approach 1:
The cell stack is pre-compressed to a controlled degree before insertion, ensuring it is compressed enough to be inserted without damage but not so much that excessive tension is lost upon release. This preliminary action optimizes the compression level for safe insertion while retaining adequate pre-tension.
Solution Approach 2:
The compression parameters (force, duration, level) are carefully controlled and adjusted during the pre-compression process. By changing these parameters optimally, the cell stack achieves the right balance between being compressible for insertion and retaining sufficient pre-tension after clamp release.
3Reliability
If the end plate is fixed to side walls by welding or bolting, then the end plate position can be secured, but the assembly process becomes time-consuming and prone to error
Solution Approach 1:
Traditional mechanical fixation methods like welding or bolting are replaced with a snap-fit mechanism. The end plate includes engagement elements that snap into corresponding features on the side walls, providing secure positioning without requiring time-consuming welding or bolting operations.
Solution Approach 2:
The end plate is designed with self-aligning and self-fixing features. The engagement elements automatically snap into place when the end plate is installed, eliminating the need for additional fixation steps and reducing assembly time while maintaining positioning accuracy.
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 snap-fit mechanism simplifies assembly, ensures consistent compression of the cell stack, and maintains pressure without the need for additional fixation methods like welding, enhancing manufacturing efficiency and reliability.
Implementation Method 1
first interlocking elements adapted to interlock with second interlocking elements of the frame walls in a fixture position of the end plate for establishing a snap fit between the end plate and the frame walls
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
The present disclosure refers to a battery system (100) including a plurality of battery cells (12) arranged along a stacking axis (A) to form a cell stack (10), and a cell stack frame (20) accommodating the cell stack (10), wherein the cell stack frame (20) includes frame walls (24, 25) and an end plate (22), wherein the end plate (22) includes, at opposite lateral sides thereof, first interlocking elements (230) which are adapted to interlock with second interlocking elements (232) of the frame walls (24, 25) in a fixture position of the end plate (22) for establishing a snap fit between the end plate (22) and the frame walls (24, 25) such that the end plate (22) exerts a pressure onto the cell stack (10), and wherein the end plate (22) comprises a plate element (221) facing the cell stack (10) and, in the fixture position, exerting the pressure onto the cell stack (10), and lateral wall elements (222, 224) extending from the plate element (221) in a direction away from the cell stack (10).