Battery Pack Locking Member for Low-Force Cell Assembly
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Solution Overview
Problem
Existing battery assemblies, such as clamshells in electric vehicles, face challenges in assembly due to the need for significant force in snap-fitting parts together and difficulty in disassembly for recycling, particularly in larger assemblies with multiple cells.
Innovation Solution
A battery assembly utilizing a tongue-in-hole arrangement with a locking member that requires less pressure to lock and is easier to release, eliminating the need for screws or threaded fasteners, and featuring posts extending from batteries, a receiver, and a locking member for engagement, along with a base plate and insulator plates for enhanced structural integrity and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a snap-fit arrangement is used to assemble battery parts, then the assembly avoids the need for welding and complex fasteners, but significant force is required to snap fit the parts together particularly for larger assemblies
Solution Approach 1:
The patent replaces the snap-fit mechanical system with a hybrid system combining welding and mechanical lugs. The lugs engage with slots to provide mechanical retention while welding creates permanent bonds at critical connection points, reducing the force needed during assembly compared to pure snap-fit methods.
Solution Approach 2:
The assembly system is segmented into multiple connection mechanisms: mechanical lugs for positioning and retention, welding for permanent bonding, and slots for guidance. This segmentation allows each mechanism to perform its optimal function, with lugs providing easy engagement and welding providing strong permanent connections.
2Ease of manufacture
If a snap-fit arrangement is used to assemble battery parts, then the assembly avoids the need for welding and complex fasteners, but it is difficult to release the parts of the assembly for recycling
Solution Approach 1:
The connection system is segmented into reversible mechanical elements (lugs and slots) and permanent welding elements. The mechanical lugs can be easily disengaged for recycling while welded connections provide permanent bonding during operation, allowing selective disassembly for maintenance and recycling purposes.
3Strength
If screws or threaded fasteners are used to secure battery components, then the assembly achieves strong mechanical bonding, but the assembly complexity increases and assembly time is extended
Solution Approach 1:
The patent replaces screws and threaded fasteners with a welding and mechanical lug system. Welding provides strong permanent bonding without the complexity of threaded fasteners, while mechanical lugs provide simple engagement features for positioning and retention during assembly.
4Force
If a locking member with tongue-in-hole arrangement is used to engage posts, then the assembly requires less pressure to lock and is easier to release, but the structural complexity increases
Solution Approach 1:
The patent extracts the locking function into a separate locking member with tongue-in-hole arrangement that engages with posts. This dedicated locking mechanism provides easy engagement and release while the rest of the assembly maintains its structural integrity through welding and mechanical lugs, distributing the complexity to a specific functional element.
Data Source
AI summary
The present invention relates to a battery assembly. The assembly includes batteries. Posts extend from the batteries. A receiver receives the posts, and a locking member engages with the received posts to lock the assembly together. Advantageously, the locking member may require less pressure to lock the assembly together and may be easier to release than the snap fit arrangement of PCT/AU2020/050604, without the need for screws or other threaded fasteners.