EV Battery Housing Fasteners With Integrated Compression Limiters
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Solution Overview
Problem
Existing electric vehicle battery covers are costly to produce due to manual addition of compression limiters, and nuts in vehicle assemblies are vulnerable to water ingress through bottom holes.
Innovation Solution
Integrated compression limiters in fasteners and a nut insertion tool for secure fastening without bottom holes, ensuring watertight seals and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If compression limiters are manually pressed into vacuum formed covers, then the covers can be produced, but the production cost and time increase
Solution Approach 1:
The compression limiter is merged with the fastener to create a single integrated component. This eliminates the separate step of manually pressing compression limiters into the cover, as the limiter is now built into the fastener itself. The integrated design allows the compression limiter and fastener to be installed as one unit during assembly.
Solution Approach 2:
The compression limiter is pre-integrated into the fastener during fastener manufacturing, rather than being added separately during cover assembly. This preliminary action of combining components before final assembly reduces the number of steps required during vehicle production.
2Ease of manufacture
If nuts are inserted through bottom holes for fastening, then assembly is simplified, but water can ingress through the holes and leak inside sealed assemblies
Solution Approach 1:
The compression limiter and fastener are merged into a single integrated component that maintains sealing integrity. The integrated design allows the fastener to engage with the cover and tray without requiring separate bottom holes that would compromise the water seal.
Solution Approach 2:
The integrated fastener with built-in compression limiter acts as an intermediary that provides both fastening and sealing functions. The compression limiter portion maintains contact with the cover to prevent water ingress, while the fastener portion secures the assembly, eliminating the need for separate sealing and fastening components.
3Ease of manufacture
If integrated compression limiters in fasteners are used, then manufacturing cost is reduced, but the fastener structure becomes more complex
Solution Approach 1:
The compression limiter and fastener are combined into a single molded component. This merging eliminates the need for separate parts and assembly steps, reducing manufacturing cost despite the increased complexity of the fastener structure. The integrated design allows for efficient production through single-step molding processes.
Data Source
AI summary
A vehicle battery assembly having specialized fasteners that includes an integrated compression limiter. The compression limiter provides protection for the fastening joint of a cover and a tray of a housing for the battery assembly. The battery assembly may also include nut and bolt assembly which may be installed by a nut insertion tool. The nut insertion tool allows the nut and bolt assembly to be installed without damaging the tray or the cover.