Modular Battery Pack Adapter Plate Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery mounting strategies for vehicular applications are complex, costly, and inefficient due to high part counts, tolerance issues, and manufacturing complexities, making it difficult to accommodate various battery pack sizes and configurations.
Innovation Solution
A modular design featuring sub-module assemblies with a box-like structure formed by brackets and end plates that allow for flexible attachment to a primary support structure, enabling easy variation in battery pack configurations and reducing the need for welding and fasteners, while adapter plates facilitate secure connections and accommodate different power and size requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting strategies with numerous components and welding processes are used, then battery cells can be securely mounted, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple mounting functions into a single integrated adapter plate that simultaneously provides structural support, battery cell retention, and alignment features. This eliminates the need for separate mounting brackets, fasteners, and alignment fixtures, thereby reducing manufacturing complexity while maintaining mounting security.
Solution Approach 2:
The adapter plate is designed as a universal component that can accommodate different battery cell configurations and mounting requirements through standardized features. This multi-functional design allows the same component to serve multiple purposes including structural support, cell retention, alignment, and interface with various vehicle platforms, reducing the need for multiple specialized parts.
2Strength
If compression limiters with tie rods are used to secure battery cells, then the battery stack is held together, but tolerance problems and assembly difficulties arise due to dimensional inconsistencies
Solution Approach 1:
The patent transitions from rigid mechanical fastening with tight tolerance requirements to a compliant mounting system that accommodates dimensional variations. The adapter plate incorporates flexible or compliant features that allow for tolerance accumulation without compromising the holding force, thereby maintaining stack integrity while reducing sensitivity to manufacturing precision.
Solution Approach 2:
The adapter plate serves as an intermediary component between the battery stack and the mounting structure, absorbing and compensating for dimensional inconsistencies. This mediator layer isolates the tolerance issues from the critical mounting interface, allowing for easier assembly while maintaining the necessary holding force.
3Manufacturing precision
If multiple components such as compression bands and hold-down rails are added, then proper dimensions and support are ensured, but the part count increases and modularity is reduced
Solution Approach 1:
The patent integrates the functions of compression bands, hold-down rails, and mounting brackets into a single adapter plate component. This consolidation maintains dimensional control and structural support functions while eliminating the need for multiple separate parts, thereby reducing the overall part count and improving modularity.
Solution Approach 2:
The adapter plate is designed as a multi-functional component that simultaneously performs the roles of compression bands, hold-down rails, and mounting brackets. This universal design provides all necessary dimensional control and support functions through a single part, reducing complexity while maintaining manufacturing precision.
4Strength
If welding and laser welding processes are used for mounting, then strong joints are achieved, but excessive temperatures and weld flash problems occur
Solution Approach 1:
The patent replaces thermal welding processes with mechanical fastening methods using the adapter plate. This substitution eliminates the harmful thermal effects of welding and laser welding while achieving equivalent or superior joint strength through optimized mechanical attachment features, thereby avoiding thermal damage to battery cells and surrounding components.
Data Source
AI summary
A modular battery pack and method of making a battery pack. The modular structure includes an open box with an interlocking features to allow for flexibility in assembly of numerous battery pack configurations. The design is such that numerous sub-module assemblies are formed that can be fastened, connected or otherwise secured to a tray, frame or other underlying primary support structure. Aligned stacks of individual battery cells can be placed within the volume defined within the box-like structure so that portions of the box-like structure move in response to a spring-like force imparted by the stack of battery cells. Adapter plates facilitate the modular construction by an interlocking connection between the box-like structure and the underlying support structure.