Integrated End Block for Battery Pack Assembly
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Solution Overview
Problem
The existing battery pack manufacturing processes are costly and require a large number of parts and complex assembly processes, which complicates the production and efficiency of high-power or high-capacity battery packs needed for applications like electric vehicles.
Innovation Solution
A battery pack design that incorporates a reduced number of parts and simplified assembly processes, featuring a first end block with a frame portion and bushing member, along with a first end plate, to surround and protect battery cells, while providing an integrated structure for insulation, rigidity, and welding sites, using plastic and metal materials for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery pack designs with multiple separate components are used, then structural integrity and protection of battery cells can be achieved, but manufacturing cost increases and assembly processes become complex
Solution Approach 1:
The patent combines the end block and end plate into a single integrated component. The end block includes an accommodating portion for the battery cell and a protruding portion that forms the end plate, eliminating the need for separate assembly of these two components while maintaining structural integrity and protection of the battery cell
Solution Approach 2:
The integrated end block serves multiple functions simultaneously: it protects the battery cell from external impacts, provides structural support, and forms the end plate structure. This multi-functional design reduces the total number of components needed in the battery pack
2Adaptability or versatility
If multiple separate parts are used in battery pack construction, then functional requirements can be met, but manufacturing cost increases
Solution Approach 1:
By merging the end block and end plate into one integrated component manufactured as a single piece, the patent reduces manufacturing steps, material costs, and assembly operations while still meeting all functional requirements for battery cell protection and structural support
3Reliability
If traditional assembly processes with many components are used, then adequate protection and support for battery cells can be provided, but production time and complexity increase
Solution Approach 1:
The integrated end block design allows for single-step assembly where the combined component is installed as one unit, reducing assembly time and complexity while maintaining adequate protection and support for the battery cell through its multi-functional structure
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 reduces manufacturing costs and simplifies assembly by integrating multiple functions into fewer parts, enhancing the structural integrity and insulation of battery packs while maintaining efficiency and reliability.
Implementation Method 1
an exposed portion exposed from the end portion and defining a welded portion with the first end plate
Data Source
AI summary
A battery pack includes: a plurality of battery cells; a first end plate on an outer side of a first battery cell of the plurality of battery cells that is arranged at an outermost side of the plurality of battery cells; and a first end block between the first end plate and the first battery cell, the first end block includes: a frame portion on an inner side of the first end block and facing the first battery cell, the frame portion surrounding edge portions of the first battery cell; and an end portion on an outer side which is a side opposite to that of the first battery cell, the end portion surrounding a bushing member, and the bushing member includes: fixing portions surrounded by the end portion; and an exposed portion exposed from the end portion to define a welded portion with the first end plate.