Traction Battery Pack Cell Stack Insertion Without Array Frames
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Solution Overview
Problem
Existing traction battery pack assemblies face challenges in efficiently aligning and securing cell stacks within an enclosure structure without the need for conventional array support structures, such as array frames, spacers, and rails, while maintaining compressive forces.
Innovation Solution
A method involving a compression machine that engages load plates at the ends of the cell stack, aligns it with an enclosure structure, and inserts it into a cell-receiving opening, followed by disengaging the compression machine using prongs that retract into clearance grooves, with optional adhesive introduction to secure the stack in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional array support structures are used to hold cell stacks, then structural stability is improved, but device complexity and assembly time increase
Solution Approach 1:
The patent removes conventional array support structures from the battery pack design. Instead of using separate support structures to hold cell stacks, the enclosure structure itself is designed to directly receive and secure the cell stacks through compression and adhesive bonding, eliminating unnecessary components and simplifying the overall device.
Solution Approach 2:
The enclosure structure serves multiple functions: it provides structural support, holds the cell stacks in position, applies compression force, and serves as the mounting structure for electrical connections. By making the enclosure multi-functional, the patent eliminates the need for separate support structures while maintaining structural stability.
2Stability of the object's composition
If conventional array support structures are used to hold cell stacks, then structural stability is improved, but assembly time and productivity decrease
Solution Approach 1:
The patent combines the functions of support structures, compression mechanisms, and mounting features into a single integrated enclosure structure. This merging allows the cell stacks to be directly inserted and secured without requiring separate assembly steps for support structures, significantly reducing assembly time while maintaining structural stability.
Solution Approach 2:
The enclosure structure is pre-designed with integrated compression and securing features that prepare the assembly process in advance. The compression machine and adhesive application are built into the enclosure design, allowing cell stacks to be quickly inserted and secured in a single operation rather than requiring multiple sequential steps.
3Manufacturing precision
If precise alignment is achieved during cell stack insertion, then manufacturing precision is improved, but alignment time and complexity increase
Solution Approach 1:
The enclosure structure includes self-aligning features such as guide rails, positioning slots, or geometric constraints that automatically align the cell stacks during insertion. The compression machine and enclosure work together to self-correct minor misalignments, achieving precise positioning without requiring complex external alignment equipment or manual adjustment.
Solution Approach 2:
The patent introduces intermediary alignment features between the cell stacks and enclosure, such as positioning pins, guide surfaces, or compliant elements that facilitate precise alignment during insertion. These intermediaries bridge the gap between rough positioning and final precise alignment, reducing both time and complexity.
4Strength
If compression force is applied to secure cell stacks, then structural integrity is improved, but risk of cell damage increases
Solution Approach 1:
The patent carefully controls compression parameters including force magnitude, application rate, and duration. The compression machine applies force gradually and maintains it within optimal ranges to secure cell stacks without exceeding damage thresholds. Adhesive bonding is used in conjunction with compression to reduce the required compression force, further minimizing damage risk.
Solution Approach 2:
The enclosure structure includes cushioning elements or compliant features that are positioned between the compression machine and cell stacks. These cushioning elements absorb excess compression force and prevent direct transmission of damaging peaks to the cells, while still maintaining sufficient compression for structural integrity.
Data Source
AI summary
A battery pack assembly method includes holding a cell stack with a compression machine. The compression machine engages a first load plate at a first end of the cell stack and a second load plate at an opposite, second end of the cell stack during the holding. The method further includes aligning the cell stack relative to an enclosure structure while the compression machine holds the cell stack, inserting the cell stack into a cell-receiving opening of an enclosure structure, and disengaging the compression machine from the first load plate and the second load plate.