Battery Pack Retention via Snap-Fit Extrusion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack designs face challenges in securely retaining multiple arrays of battery cells within a limited space, particularly in electrified vehicles, where conventional fastening methods can be labor-intensive and inefficient.
Innovation Solution
The use of an extrusion with a 'C' shaped cross-sectional profile that slidably engages with the battery cell frames, featuring a snap-fit mechanism with a ridge and groove, and is secured to a support to limit movement, providing effective retention within tight packaging spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fastening methods are used to secure battery cell arrays, then the battery cells can be retained, but the installation process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces conventional mechanical fastening methods (screws, clips, adhesives) with a snap-fit retention system. The extrusion features a channel that receives the battery cell frame, and a snap-fit mechanism with a ridge and groove that engages when the extrusion is compressed during installation. This eliminates the need for tools and multiple fastening steps, dramatically reducing installation time and labor complexity.
Solution Approach 2:
The retention system is divided into distinct functional segments: the extrusion body, the channel for receiving the battery cell frame, the snap-fit feature with ridge and groove, and the end cap. This segmentation allows for simplified manufacturing of individual components and easy assembly, where the extrusion can be installed as a single piece that engages with the battery cell frame through the snap-fit mechanism without requiring complex multi-step fastening procedures.
2Reliability
If multiple fastening points are used to secure battery cell arrays, then retention reliability improves, but device complexity increases
Solution Approach 1:
The extrusion serves multiple functions simultaneously: it provides a channel to receive and guide the battery cell frame, incorporates a snap-fit mechanism for secure retention, and includes an end cap to complete the engagement. This multi-functional design achieves reliable retention of the entire battery cell array through a single component rather than requiring multiple separate fasteners at different locations, thereby maintaining reliability while reducing overall system complexity.
3Strength
If extrusion thickness is increased to provide added strength, then retention strength improves, but manufacturing cost and material usage increase
Solution Approach 1:
The extrusion is designed with varying thicknesses at different locations to optimize material usage. The walls of the channel and the snap-fit feature have sufficient thickness to provide the necessary strength for secure engagement and retention. The end cap is designed with adequate thickness to complete the engagement and distribute loads. This localized thickness optimization ensures that material is used only where structurally necessary, achieving high retention strength without excessive material consumption.
Data Source
AI summary
An exemplary method of securing portions of a battery pack includes, among other things, slidably engaging a portion of a battery cell frame within a channel of an extrusion, and securing the extrusion to a support to secure the battery cell frame.