Battery Pack Side-Cover Groove Assembly to Prevent Jamming
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Solution Overview
Problem
Traditional battery housings face challenges with complex and inefficient installation processes due to the use of multiple side covers and fasteners, leading to undesirable installation efficiency and potential jamming issues.
Innovation Solution
A battery pack design featuring two first side covers with abutting parts and two second side covers, where the abutting parts are inserted into grooves of the battery cell module, allowing for easy assembly and connection with end covers, along with cushioning and heat dissipation structures for improved stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery housing uses six side covers with fasteners to enclose battery cell modules, then the battery housing provides secure enclosure, but the installation process becomes complex and time-consuming
Solution Approach 1:
The patent extracts the fastening function from the side covers by introducing a separate plate structure with through holes. The plate is positioned over the battery cell modules and secured with fasteners, while the side covers themselves become simple enclosing structures without integrated fastening mechanisms. This separation simplifies the side cover design and assembly process.
Solution Approach 2:
The battery housing is segmented into distinct functional components: six side covers for enclosure, a separate plate structure for fastening, and end covers for closure. Each component performs its specific function independently, allowing for simplified manufacturing and assembly. The side covers focus solely on enclosure while the plate handles all fastening operations.
2Reliability
If traditional battery housing uses integrated fasteners in side covers, then the enclosure is secure, but installation efficiency decreases
Solution Approach 1:
The plate structure is designed with pre-positioned through holes that align with battery cell module locations before assembly. This preliminary positioning arrangement allows for rapid installation by simply inserting fasteners through the pre-aligned holes, eliminating the need for complex fastening operations during the assembly process.
Solution Approach 2:
The plate structure serves as an intermediary component between the side covers and the battery cell modules. It provides a centralized fastening interface that simplifies the connection process, allowing multiple battery cell modules to be secured simultaneously through a single plate structure rather than individual fastening operations on each side cover.
3Manufacturing precision
If highly accurate shell is used to ensure battery cell module enters cavity, then the fit is precise, but any jam causes the shell to be scrapped
Solution Approach 1:
The patent introduces cushions positioned between the end covers and the battery cell modules. These cushions provide compliance and tolerance compensation during assembly, allowing the battery cell modules to be properly positioned without requiring extremely precise shell dimensions. The cushions absorb dimensional variations and prevent jamming, reducing scrap rates while maintaining proper fit.
Data Source
AI summary
A battery cell module includes a plurality of battery cells stacked in a first direction, and a first groove extending in the first direction is formed at each of two ends of the first side of the battery cell module. In a second direction, the two first side covers are arranged at two opposite sides of the battery cell module. First bodies of the two first side covers are substantially parallel to a third direction of the battery cell module, and each of the first side covers is provided with an abutting part. The abutting part extends from an edge of the first side cover and is substantially perpendicular to the first body and is connected to a groove wall of the first groove. The two second side covers and the two first side covers are fastened to each other. The abutting part is inserted into the first groove.