Dismountable Battery Impactor Structure for Adhesive Bead Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing traction battery designs face challenges in maintaining structural integrity during disassembly and reassembly, as cutting the impactor to access the adhesive bead weakens its ability to transmit impact forces effectively, posing a risk to battery components during maintenance.
Innovation Solution
A two-part cover system is introduced, comprising a side piece and an impactor piece that are separately attachable, allowing easy disassembly and reassembly without compromising the impactor's structural integrity, with the impactor piece masking the adhesive bead and being fixed to the side piece via screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed impactor is integrated into the battery housing, then the battery structure is stable and robust, but the impactor cannot be reused after a single use and replacement is costly
Solution Approach 1:
The impactor is divided into a removable impactor part that can be separated from the battery housing. This allows the impactor part to be replaced independently without replacing the entire battery assembly, reducing costs while maintaining structural integrity through the reusable housing and connection interface.
Solution Approach 2:
The impactor part is designed as a disposable component that can be discarded after use, while the battery housing and connection interfaces are recovered and reused. This approach eliminates the need to replace the entire impactor assembly, reducing waste and replacement costs.
2Ease of manufacture
If the battery housing is made from a single material, then manufacturing is simple and cost-effective, but selective cutting of adhesive without damaging surrounding components is difficult
Solution Approach 1:
The battery housing is constructed with different materials in different regions: a first material for the main housing body and a second material for the adhesive portion. This allows the impactor to selectively cut the adhesive with different cutting characteristics while maintaining overall manufacturing efficiency and cost-effectiveness.
Solution Approach 2:
The battery housing uses a composite structure combining at least two different materials - one for the housing body and another for the adhesive. This composite approach enables selective cutting of the adhesive layer while preserving surrounding components, achieving precise adhesive removal without compromising the simplicity of manufacturing.
3Strength
If adhesive is used to secure the impactor to the battery housing, then the impactor is firmly fixed during operation, but residual adhesive causes contamination and additional cleaning steps are required
Solution Approach 1:
The connection between the impactor part and battery housing is achieved by extracting the adhesive entirely from the connection interface. Instead of using adhesive, the design employs direct mechanical connection through the connection interface, eliminating adhesive contamination while maintaining secure fixation during operation.
Solution Approach 2:
The adhesive bonding system is replaced with a mechanical connection system through the connection interface. This substitution eliminates the harmful effects of adhesive residue and contamination while providing reliable fixation of the impactor part to the battery housing during impact operations.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a traction battery for a motor vehicle, the traction battery comprising a cover in two parts, which two parts are configured to be bonded together by means of at least one bead of adhesive (C3), the battery comprising a sidewall part (PF) for a battery sidewall, this part being configured to attach the battery to a vehicle body, and an impactor part (PI) configured to protect the battery from side impacts, the impactor part (PI) being configured to be attached to the sidewall part (PF) to form a battery sidewall in such a way that the impactor part (PI) at least partially conceals the bead of adhesive (C3), characterised in that the impactor part (PI) and the sidewall part (PF) are separate parts, and are dismountably attached to one another. The invention also relates to a dismounting method and to a vehicle based on such a battery.