Battery Pack Spacer Recess Structure for Interference-Free Assembly
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Solution Overview
Problem
Battery packs face challenges in maintaining assemblability when constituent members with convex portions project towards each other, leading to interference and assembly issues.
Innovation Solution
A battery pack design that includes a spacer with a convex portion projecting towards a holding member, which has an accommodating recess to prevent interference, ensuring proper assembly and improved rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spacer with a convex portion is provided between batteries to maintain spacing and insulation, then the insulation and spacing between adjacent batteries is improved, but the convex portion may interfere with the holding member and prevent proper assembly
Solution Approach 1:
The accommodating portion in the holding member is designed to receive and nest the convex portion of the spacer, allowing the convex portion to be integrated within the holding member's structure rather than protruding outward. This nesting approach eliminates interference while maintaining the spacer's insulating function.
Solution Approach 2:
The accommodating portion acts as an intermediary feature that mediates between the convex portion of the spacer and the holding member body. It provides a dedicated space that allows the convex portion to exist without causing interference, enabling both components to coexist harmoniously in the assembly.
2Ease of operation
If the holding member is designed to accommodate the convex portion of the spacer, then assemblability is maintained, but the structure becomes more complex
Solution Approach 1:
The accommodating portion is merged into the holding member's existing structure, combining the functions of spacing accommodation and structural support in a single integrated component. This reduces the need for separate parts while maintaining assemblability.
Solution Approach 2:
The accommodating portion is provided only at the specific location where the convex portion needs to be received, rather than redesigning the entire holding member. This localized approach adds minimal complexity while solving the assembly issue.
3Ease of manufacture
If the accommodating portion is provided in the holding member to receive the convex portion, then interference is prevented and assembly is facilitated, but manufacturing complexity increases
Solution Approach 1:
The accommodating portion is formed as an integrated feature of the holding member in a single molding process, combining multiple functions (structural support, spacer accommodation, assembly guidance) into one manufacturing step. This avoids the need for separate parts or post-assembly operations.
Solution Approach 2:
The accommodating portion serves multiple functions simultaneously: it receives the convex portion for proper positioning, provides assembly guidance, and ensures correct spacing. This multi-functionality reduces the need for additional features or parts, offsetting the increased molding complexity.
Data Source
AI summary
A battery pack 1 includes: a plurality of stacked batteries 100; a spacer (a cell spacer 202, a first intermediate spacer 203, and a second intermediate spacer 204) which is provided between the batteries 100 adjacent to each other along the stacking direction X of the battery 100 and holds the adjacent batteries 100; and a holding member (a first side plate 231 and a second side plate 232) which holds the plurality of batteries 100 along the stacking direction X. For example, the cell spacer 202 includes a convex portion 202a projecting from the battery 100 toward, for example, the second side plate 232. For example, the second side plate 232 includes an accommodating portion 232d having a recessed depression to accommodate the convex portion 202a.