Battery Pack Endplate External Retention via Enclosure Wall
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Solution Overview
Problem
Existing methods for securing battery arrays within a battery pack enclosure require significant packaging space and often necessitate securing mechanisms that extend laterally from the endplate, increasing the overall size of the battery pack.
Innovation Solution
The solution involves securing the enclosure wall directly to the endplate using mechanical fasteners that engage bores on the endplate, either through apertures in the enclosure wall and a bracket or through raised ribs, allowing for external access and reducing the need for lateral extensions, thus minimizing packaging space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional securing mechanisms are used to secure battery arrays within the battery pack enclosure, then the battery arrays are held in place, but significant packaging space is required and the overall size of the battery pack increases
Solution Approach 1:
The patent transitions from lateral/securing mechanisms to a longitudinal approach by extending the endplate through the enclosure wall. This dimensional change allows the securing function to be achieved from the opposite direction, eliminating the need for lateral extensions and reducing packaging space requirements.
Solution Approach 2:
Instead of securing the battery array from the inside of the enclosure (traditional approach), the patent inverts the approach by extending the endplate through the enclosure wall and securing it from the outside. This inversion eliminates the need for internal securing mechanisms and reduces the packaging footprint.
2Stability of the object's composition
If lateral extensions are used to secure the battery array, then the battery array is stabilized, but the overall size of the battery pack increases
Solution Approach 1:
The patent eliminates lateral extensions by transitioning to a longitudinal securing approach. The endplate extends through the enclosure wall in the longitudinal direction, providing stability without requiring lateral space, thus reducing the battery pack footprint.
Solution Approach 2:
The patent extracts the lateral extension components from the design and replaces them with a through-extension approach. By removing the lateral extensions and using the endplate extension through the enclosure wall, the same stabilizing function is achieved with reduced footprint.
3Reliability
If complex securing mechanisms are used to hold the battery array, then secure attachment is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the endplate and enclosure wall into a single integrated structure where the endplate extends directly through the enclosure wall. This consolidation eliminates the need for separate securing mechanisms, brackets, or fasteners, thereby reducing manufacturing complexity while maintaining secure attachment.
Solution Approach 2:
The endplate serves multiple functions: it closes the battery array, extends through the enclosure wall, and provides the securing interface. This multi-functionality eliminates the need for separate securing components, simplifying the overall design and manufacturing process.
Data Source
AI summary
An exemplary battery assembly includes an endplate of a battery array, and an enclosure wall secured directly to the endplate from outside an open area of a battery pack enclosure. An exemplary method of securing a battery array includes positioning a battery array within an open area of an enclosure and, from a position outside the open area, securing an endplate of a battery array directly to a wall of a battery pack enclosure.