Battery Pack Expansion Gap Structure for Damage-Free Module Assembly
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Solution Overview
Problem
The interference fit of battery modules in battery boxes often causes deformation and damage due to squeezing, leading to inefficient space utilization and assembly challenges.
Innovation Solution
A battery pack design featuring a battery box with a separator that forms an expansion gap or structure between two battery assemblies, allowing for gradual compaction and preventing damage during assembly and disassembly, while improving space utilization and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery modules are interference fitted into the battery box to improve space utilization, then space utilization rate is improved, but battery modules are squeezed and deformed causing damage to battery structure
Solution Approach 1:
The patent applies preliminary action by pre-forming expansion gaps between battery modules during assembly. These gaps are created before final compression, allowing controlled deformation progression that prevents sudden structural failure while achieving high space utilization. The expansion gaps are deliberately designed in advance to manage the interference fit process.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating expansion gaps that act as buffer zones during assembly. These gaps provide gradual deformation capacity, cushioning the impact of interference fit on battery module structures. The gaps prevent direct rigid contact between modules, distributing compression forces to avoid localized damage.
2Productivity
If battery modules are clamped through tooling to improve assembly efficiency, then assembly efficiency is improved, but batteries are squeezed and deformed resulting in damage to battery structure
Solution Approach 1:
The patent applies preliminary action by pre-designing expansion gaps and flexible connection structures before assembly. This allows tooling to clamp modules efficiently without causing deformation, as the gaps and flexible connections are already in place to accommodate compression forces during the high-speed assembly process.
Solution Approach 2:
The patent changes physical parameters by introducing expansion gaps that alter the rigidity and compressibility of the battery module arrangement. This parameter change allows tooling to apply clamping forces for efficient assembly while the gaps and flexible connections absorb deformation, preventing structural damage.
3Volume of moving object
If battery modules are tightly arranged to improve space utilization, then space utilization rate is improved, but disassembly becomes difficult
Solution Approach 1:
The patent applies segmentation by dividing the battery pack into modular units separated by expansion gaps. These gaps create natural separation zones that allow modules to be easily disconnected during disassembly, even when tightly arranged for high space utilization. The flexible connections are segmented to facilitate module removal.
Solution Approach 2:
The patent implements dynamics by designing expansion gaps and flexible connections that can dynamically adjust during assembly and disassembly. The gaps allow modules to move relative to each other, enabling easy separation during disassembly while maintaining tight arrangement during operation for optimal space utilization.
Data Source
AI summary
A battery pack, an assembly method thereof, and a disassembly method thereof are provided. The battery pack includes a battery box, a first battery assembly, a second battery assembly, and a separator. The separator is located between the second battery assembly and the first battery assembly. An expansion gap is formed between a first surface and a second surface, the expansion gap gradually expands from a second direction, and/or an expansion structure is formed between a third surface and a fourth surface, the expansion structure gradually expands from a second direction. The second direction is perpendicular to the first direction, and the second direction extends from a bottom surface of the battery box toward a top surface of the battery box.