Battery Pack Mounting Insert for Automated Assembly
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Solution Overview
Problem
The existing methods for mounting battery packs to vehicle carrying structures are complex and hinder automation due to the need for separate anti-corrosion coatings, additional sealing, and twist protection elements, especially when using different materials like steel bushings and aluminum frames.
Innovation Solution
A battery pack design featuring slots with inserts made of the same material as the framework, allowing for simplified and automated mounting with screws passing through central through-holes, eliminating the need for separate anti-corrosion coatings and twist protection, and enabling easy sealing with a flat gasket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel bushings with anti-corrosion coatings are used for mounting battery packs, then corrosion protection is improved, but device complexity and manufacturing complexity increase due to additional coating processes and twist protection elements
Solution Approach 1:
The patent merges the mounting element and the anti-corrosion protection into a single aluminum alloy component. The aluminum framework itself serves as both the structural mounting element and the corrosion-resistant component, eliminating the need for separate steel bushings and anti-corrosion coating processes. This integration resolves the contradiction by reducing device complexity while maintaining corrosion protection through material selection.
Solution Approach 2:
The patent uses homogeneous material (aluminum alloy) for both the framework and mounting elements. By making the mounting elements from the same aluminum alloy as the framework, the patent eliminates material incompatibility, removes the need for anti-corrosion coatings on dissimilar metals, and simplifies the overall structure. This homogeneity approach directly addresses the contradiction by reducing complexity while ensuring corrosion resistance.
2Reliability
If steel bushings with separate anti-corrosion coatings are used, then corrosion protection is improved, but ease of manufacture decreases due to multiple processing steps including coating and sealing
Solution Approach 1:
The patent combines the mounting function and corrosion protection function into a single aluminum alloy component. This merging eliminates multiple manufacturing steps such as applying anti-corrosion coatings, adding twist protection elements, and performing separate sealing operations. The aluminum alloy mounting elements are directly formed during framework manufacturing, significantly improving ease of manufacture while maintaining corrosion protection.
Solution Approach 2:
The aluminum alloy framework and mounting elements provide their own corrosion protection through their inherent material properties. The aluminum alloy naturally forms a protective oxide layer, eliminating the need for external anti-corrosion coatings or protective services. This self-service approach simplifies manufacturing by removing additional processing steps while ensuring reliable corrosion protection.
3Strength
If complex mounting structures with multiple components are used, then mechanical stability is improved, but productivity decreases due to hindered automation of the mounting process
Solution Approach 1:
The patent merges multiple mounting components into a single integrated aluminum alloy framework structure. The mounting elements are directly formed as part of the framework, eliminating the need for separate assembly steps involving multiple components. This integration maintains mechanical stability through the rigid aluminum alloy structure while enabling automated mounting processes by reducing the number of parts and assembly operations required.
Solution Approach 2:
The patent segments the mounting function into simple, standardized aluminum alloy elements with through-holes that are directly formed during framework manufacturing. This segmentation approach creates simple, repeatable mounting features that are ideal for automated processes, while the overall mechanical stability is maintained through the distributed arrangement of these standardized elements throughout the framework structure.
Data Source
AI summary
A battery pack for a vehicle is provided. The battery pack comprises: at least one battery module including a plurality of secondary battery cells, a metal framework for supporting the at least one battery module, the framework including a plurality of slots extending from a bottom side to an opposing mounting side of the battery pack, and an insert tightly positioned within each slot, the insert being made of a similar material as the framework and including a through-hole adapted for accommodating a fixation element.