Battery Pack Clamping Assembly for Potting Foam Expansion
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Solution Overview
Problem
Batteries packs bulge and fail to comply with dimensional tolerances due to pressure exerted by expanding potting foam during encapsulation.
Innovation Solution
A tool assembly and method that applies a clamping force using a clamp with a movable clamping arm and springs to minimize deformation during potting material expansion, while allowing controlled deflection and using a heater to accelerate curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the battery pack is filled with potting material without clamping, then the potting material can expand freely to encapsulate components, but the battery pack bulges and fails to comply with dimensional tolerances
Solution Approach 1:
The clamp applies a clamping force to the battery pack before and during the expansion of the potting material. This preliminary counteracting force prevents the pack from bulging as the foam expands, thereby maintaining dimensional tolerances and preventing deformation.
2Manufacturing precision
If a rigid clamp is used to prevent bulging, then dimensional tolerances are maintained, but the clamp may cause damage to the battery pack components
Solution Approach 1:
The clamp applies force through distributed contact surfaces including the first contact surface on the clamp arm and the second contact surface on the base plate. These distributed contact areas spread the clamping force across multiple points, preventing concentration of stress that could damage battery pack components while still maintaining overall dimensional control.
Solution Approach 2:
The clamp arm is configured to be movable relative to the base plate, allowing the clamp to dynamically adjust to the expansion forces of the potting material. This mobility enables the clamp to maintain consistent clamping force throughout the expansion process without creating rigid stress points that could damage components.
3Manufacturing precision
If the clamp applies high clamping force to control expansion, then dimensional tolerances are met, but the battery pack structure may be deformed
Solution Approach 1:
The clamp is designed with specific contact surfaces positioned at strategic locations on the battery pack. The first contact surface on the clamp arm and the second contact surface on the base plate are positioned to apply force at optimal points that control expansion without creating deformation in critical structural areas of the battery pack.
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
Minimizes battery pack deformation and ensures compliance with dimensional tolerances by controlling foam expansion and reducing cycle time.
Implementation Method 1
The clamp includes a clamping arm and a rigid base plate. The clamping arm is movable relative to the rigid base plate. The tool assembly includes a spring coupled to the clamping arm.
Implementation Method 2
The tool assembly includes a heater exchanger in thermal communication with the central clamping portion. The method may include heating the central clamping portion of the clamp.
Implementation Method 3
Batteries packs are filled with potting foam to encapsulate internal components inside the battery packs. The pressure exerted on the battery pack by the foam expansion would cause the pack to bulge.
Data Source
AI summary
A method for manufacturing a battery includes filling a battery pack with a potting material and clamping the battery pack with a clamp to apply a clamping force on the battery back while the potting material is inside the battery pack. The clamp includes a clamping arm and a rigid base plate. The method further includes maintaining the clamping force on the battery pack while the potting material foams to minimize deformation of the battery pack while the potting material expands during curing. Further, the method further includes unclamping the battery pack.