Battery Pack Casing Integrated Screws Simplify Mounting
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Solution Overview
Problem
Conventional battery packs face challenges in simplifying the structure for attachment to a mount, which can lead to increased manufacturing costs and complexity due to the use of separate screws for connection, and may result in inefficient heat transfer and space utilization.
Innovation Solution
The battery pack incorporates a casing with integrated second screws on the end walls, allowing for direct attachment to brackets via bolts, while maintaining efficient heat transfer through a conductive member and optimizing space usage by offsetting connectors and nuts, thus simplifying the structure and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate screws are used for connecting battery pack divided parts, then the connection structure is established, but the manufacturing cost and structural complexity increase
Solution Approach 1:
The patent integrates the screw connection structure directly into the casing walls by forming male screw threads on one casing wall and corresponding female screw threads on the opposing casing wall. This merging of separate connection components into the structural walls themselves eliminates the need for additional separate screws, thereby reducing manufacturing cost and structural complexity while maintaining reliable mechanical connection between battery cell groups.
2Reliability
If conventional screw connection method is used, then battery cells are connected, but heat transfer efficiency is reduced
Solution Approach 1:
The screw connection structure is integrated directly into the thermally conductive casing walls, creating a unified thermal pathway. The male and female screw threads are formed as part of the casing structure itself, allowing heat to flow continuously through the connection interface without interruption from separate fastening components. This merging ensures that the mechanical connection and thermal conduction paths are aligned, improving heat transfer efficiency while maintaining reliable electrical and mechanical connection between battery cells.
3Reliability
If connectors and screws are positioned conventionally, then electrical connection is established, but space utilization is inefficient and interference occurs
Solution Approach 1:
The patent employs asymmetric positioning of connectors and screw connection structures on the casing walls. By offsetting the male and female screw threads from the connector positions and arranging them at different locations on the opposing walls, the design prevents spatial interference between electrical connectors and mechanical fastening elements. This asymmetric layout optimizes space utilization within the battery pack assembly while ensuring both electrical connection reliability and mechanical assembly capability.
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 configuration simplifies the battery pack's structure, reduces manufacturing costs, enhances heat transfer efficiency, and allows for a more compact design by effectively utilizing space, preventing interference between connectors and brackets.
Implementation Method 1
maintaining efficient heat transfer through a conductive member
Data Source
AI summary
A battery pack includes a first casing, a plurality of battery cells, and a second screw, for example. The first casing is supported by a support member and includes an insulating first outer wall. The battery cells are housed in the first casing. The first outer wall is provided with a second screw that is connectable to a first screw. The first casing is supported by the support member with the first screw fitted into the second screw, placing the support member in-between the first screw and the second screw.