Battery Pack Expansion Beam Bonding for Vibration-Resistant Cell Assembly
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Solution Overview
Problem
The existing connection between the expansion beam and the cell assembly in battery packs is unreliable, prone to disconnection during collisions or vibrations due to reliance on extrusion and friction forces, leading to potential deformation of the battery box.
Innovation Solution
The expansion beam is designed with a first side wall bonded to the cell assembly using adhesive-filled recesses and an oblique second side wall to support expansion, enhancing connection reliability, and includes weight reduction cavities and stiffeners to improve anti-expansion ability without occupying additional space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the expansion beam is connected to the cell assembly only through extrusion force and friction force, then the structure is simple, but the connection reliability is poor
Solution Approach 1:
A connection structure comprising a connection portion and a limiting portion is introduced as an intermediary between the expansion beam and the cell assembly. The connection portion engages with the cell assembly through insertion and locking mechanisms, while the limiting portion prevents disconnection during collisions or vibrations, significantly enhancing connection reliability without requiring complex welding or multiple fasteners.
Solution Approach 2:
The patent replaces the traditional mechanical connection methods (welding, bolting) with a specialized mechanical engagement system. The connection structure uses geometric interlocking features including insertion holes, protrusions, and limiting portions that create a self-locking mechanism, eliminating the need for additional fasteners or welding operations while improving reliability.
2Reliability
If the expansion beam uses a solid structure to improve connection reliability, then the connection is more reliable, but the weight and space occupation increase
Solution Approach 1:
The expansion beam employs local reinforcement only where needed for connection reliability. The connection structure includes localized thickening at the connection portion to engage with the cell assembly, while the rest of the beam maintains a thinner profile. This localized quality enhancement provides sufficient mechanical strength for reliable connection without unnecessarily increasing overall beam weight.
Solution Approach 2:
The patent utilizes composite construction by combining the expansion beam with a dedicated connection structure made of appropriate materials. The connection structure may use different material properties than the beam itself, optimizing for connection strength and reliability while keeping the beam lightweight. This composite approach allows each component to be optimized for its specific function.
3Strength
If the expansion beam is designed with thicker walls to improve anti-expansion ability, then the structural strength is improved, but the space occupation and weight increase
Solution Approach 1:
The expansion beam design applies local quality enhancement by concentrating structural reinforcement only in critical areas. The first and second side walls are thickened locally at the connection portions to provide adequate anti-expansion ability, while the intermediate sections maintain thinner profiles. This localized reinforcement achieves the required strength without proportionally increasing overall volume and space occupation.
Solution Approach 2:
The expansion beam is segmented into different functional zones with different wall thicknesses. The connection portions have thicker walls for strength and stability, while the spanning portions have thinner walls to reduce weight and space. This segmentation allows the beam to meet strength requirements for anti-expansion ability while minimizing overall volume occupation in the battery box.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design significantly reduces the likelihood of disconnection, improves connection reliability, enhances energy density, and reduces weight and production costs while maintaining assembly efficiency.
Implementation Method 1
The first side wall is bonded to the cell assembly
Data Source
Figure 1~2
Figure 3~4
AI summary
Provided is a battery pack. The battery pack includes a battery box, a cell assembly (100), and an expansion beam (200). The cell assembly (100) is disposed in the battery box. The expansion beam (200) is fixed in the battery box and includes a first side wall (210) and a second side wall (220) opposite to each other. The first side wall (210) is bonded to the cell assembly (100), significantly enhancing the reliability of the connection between the expansion beam (200) and the cell assembly (100).