Battery Pack Module Cleat Attachment for Faster EV Assembly
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Solution Overview
Problem
Existing methods for securing battery pack modules in electrified vehicles are inefficient and complex, requiring numerous mechanical fasteners and labor-intensive assembly processes.
Innovation Solution
A cleat-based attachment system is used to interlock battery pack modules to a structural member within the battery pack, utilizing upper and lower cleats, such as a French cleat system, supplemented by mechanical fasteners to secure the modules to the structural member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical fasteners are used to secure battery pack modules, then reliable attachment is achieved, but the number of fasteners increases and assembly complexity increases
Solution Approach 1:
The attachment system is segmented into modular components: a structural member with integrated attachment features, battery pack modules with corresponding attachment elements, and a simplified fastening mechanism. This segmentation allows each component to perform its function independently while reducing overall system complexity.
Solution Approach 2:
The patent merges the structural member with attachment features directly integrated into it, eliminating the need for separate complex fastening systems. The structural member combines support and attachment functions, reducing the number of discrete parts required.
2Reliability
If traditional mechanical fasteners are used to secure battery pack modules, then secure attachment is achieved, but labor time and assembly effort increase
Solution Approach 1:
The structural member is pre-configured with integrated attachment features during manufacturing, eliminating the need for complex assembly operations during battery pack assembly. The attachment system is prepared in advance, reducing on-site assembly time and labor requirements.
Solution Approach 2:
The attachment system is designed to be self-aligning and self-securing, where the modular components naturally guide themselves into the correct position during assembly, minimizing the need for manual adjustment and reducing assembly time.
Data Source
AI summary
A battery pack assembly includes a structural member of a battery pack; a module of the battery pack; and an attachment system having a plurality of cleats. The cleats can interlock to secure the module to the structural member. Mechanical fasteners can also be used to secure the module to the structural member.