Battery Pack Cover Fastening Without Cell Interference
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Solution Overview
Problem
Existing battery packs face challenges in achieving improved safety and energy density.
Innovation Solution
The battery pack design includes a housing with a plate part, multiple battery devices on the upper side, a cover plate on the lower side, and fastening members that fix the cover plate and housing. The fastening members have a head part in contact with the cover plate and a shank with a diameter less than the head part, allowing for efficient fixation without additional elements like brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fixing elements such as brackets are used to secure the cover plate, then the fixation reliability is improved, but the device complexity and energy density are worsened due to increased component count and mass
Solution Approach 1:
The fastening function is merged into the fastening members themselves, which are directly inserted through the housing to secure the cover plate. This eliminates the need for separate brackets and additional fixing elements, reducing component count while maintaining fixation reliability through the integrated fastening design
Solution Approach 2:
The fastening members serve multiple functions: they act as both structural support elements and fastening mechanisms. By combining these functions into a single component, the design reduces the number of parts needed while achieving both structural integrity and secure fixation of the cover plate
2Reliability
If additional fixing elements such as brackets are used to secure the cover plate, then the fixation reliability is improved, but the energy density is worsened due to increased mass
Solution Approach 1:
The fastening function is merged into the fastening members, eliminating separate brackets and reducing overall component mass. This directly improves energy density by removing unnecessary material while maintaining secure fixation through the integrated fastening design
Solution Approach 2:
Unnecessary fixing elements such as brackets are extracted from the design, leaving only the essential fastening members. This reduction in component mass directly improves energy density while the fastening members themselves maintain sufficient fixation reliability for the application
3Ease of operation
If fastening members are positioned to secure the cover plate, then the fixation function is improved, but safety is worsened when fastening members interfere with battery cells
Solution Approach 1:
The fastening members are designed with specific local characteristics: the head portion makes contact with the cover plate for fixation, while the shank portion is dimensioned and positioned to pass through housing openings without contacting the battery cells. This localized differentiation of contact points ensures fixation function while preventing interference with battery cells
Solution Approach 2:
The housing structure acts as an intermediary that guides and positions the fastening members. The housing openings are designed to allow the shank portion to pass through while preventing contact with the battery cells, thus mediating between the fixation requirement and the safety constraint
4Strength
If the shank diameter is increased to improve fixation strength, then the joining strength is improved, but the safety is worsened due to increased risk of interference with battery cells
Solution Approach 1:
The fastening members are designed with optimized local dimensions: the shank diameter is specifically sized to provide sufficient joining strength through the housing material while being small enough to pass through the housing openings without contacting the battery cells. This localized dimensional optimization resolves the contradiction between strength and safety
Data Source
AI summary
Discussed is a battery pack including a housing having a plate part, a plurality of battery devices on a first side of the plate part of the housing, a cover plate on a second side of the plate part of the housing, and a plurality of fastening members configured to fix the cover plate and the housing, in which each of the plurality of fastening members includes a head part and a shank, in which a diameter of the shank is less than a diameter of the head part, and the head part of each of the plurality of fastening members is in contact with the cover plate.