Battery Pack End Plate With Rotatable Collector Cover

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Solution Overview

Problem

The assembly efficiency of battery packs is low due to the need for multiple parts and the risk of parts being lost during assembly, particularly when installing a protective cover on the end plate of the battery cell assembly.

Innovation Solution

A battery pack design that includes a rotatable protective cover integrally formed with the body plate through injection molding, which covers and protects the output current collector, reducing the need for additional structural parts and simplifying the assembly process by eliminating the requirement for a metal shaft at the rotatory junction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a protective cover is provided to insulate the output current collector, then safety is improved, but assembly complexity increases due to multiple parts and risk of parts being lost

Engineering Contradiction:

ImprovesafetyVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective cover is integrally formed with the end plate through injection molding, merging two previously separate components (end plate and protective cover) into a single integrated structure. This eliminates the need for separate assembly steps, reduces the number of parts, and prevents parts from being lost during assembly, while maintaining the insulation and safety functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated end plate assembly serves multiple functions simultaneously: it provides structural support as an end plate, provides electrical insulation through the protective cover, and eliminates the need for separate fastening mechanisms. The integral structure combines the functions of mechanical support and electrical insulation in a single component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a protective cover is provided to insulate the output current collector, then safety is improved, but the number of parts increases

Engineering Contradiction:

ImprovesafetyVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The protective cover and end plate are merged into a single integral structure through injection molding, reducing the number of parts from two separate components to one unified component. This maintains the safety function of electrical insulation while eliminating the need for additional parts.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If a rotatable protective cover is used, then assembly efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveassembly efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The rotatable protective cover is integrally formed with the end plate through injection molding, combining what would traditionally be separate rotating components into a single molded part. This eliminates the need for separate rotatory junctions and metal shafts, simplifying manufacturing while maintaining the rotatable functionality for assembly efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical connection method using metal shafts and separate rotatory junctions is replaced with an integral molded structure. The rotation capability is achieved through the flexible design of the integral structure itself, eliminating complex mechanical assemblies and simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This design enhances assembly efficiency by reducing the complexity of the assembly process, improving insulation reliability, and preventing accidental contact with the output current collector, thereby increasing the safety and reliability of the battery pack.

Implementation Method 1

the protective cover and the body plate are integrally formed through injection molding

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

the output current collector is configured to output electric energy of the battery cell assembly

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

a protective cover may be provided to insulate the output current collector

Methodology Applied

Scientific EffectElectrical insulation:

Data Source

PatentUS11848456B2Battery pack and vehicle

Publication Date: 2023.12.19 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

This application discloses a battery pack and a vehicle, including: a case assembly, including an accommodating cavity; a battery module, disposed in the accommodating cavity, wherein the battery module includes a battery cell assembly, where the battery cell assembly includes an output current collector and a plurality of battery cells arranged side by side along a first direction of the battery pack, and the output current collector is configured to output electric energy of the battery cell assembly; and an end plate assembly, including a body plate and a protective cover, where the body plate is located at an end of the battery cell assembly along the first direction, the protective cover is rotatably connected to the body plate, and at least a part of the output current collector is located between the body plate and the protective cover.