Battery Pack Enclosure Turned Flange for Compact Rim Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery pack enclosures face challenges in maintaining structural integrity and compact size due to inconsistently distributed reinforcement fibers, leading to larger packaging footprints as attachment rims extend outward to compensate for fiber distribution.
Innovation Solution
The use of a stand-off with a platform portion and a turned flange in the attachment rim, which includes interfacing regions and stand-offs, allows for secure fastening and adequate reinforcement without extending the enclosure's size, ensuring strength and attachment characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the attachment rim extends outward to compensate for inconsistent fiber distribution, then structural integrity is improved, but the packaging footprint increases
Solution Approach 1:
The attachment rim is extended in the vertical dimension through the turned flange rather than only in the horizontal plane. The flange portion extends downward from the platform, providing additional structural reinforcement and fiber distribution area in the vertical direction, which compensates for inconsistent fiber distribution without increasing the horizontal packaging footprint.
Solution Approach 2:
The attachment rim incorporates a turned flange structure that creates a composite geometric form combining a horizontal platform portion and a vertical flange portion. This composite structure provides both the necessary structural integrity for fastener attachment and adequate surface area for fiber distribution, resolving the contradiction between strength and footprint.
2Reliability
If the attachment rim extends outward to provide adequate reinforcement, then attachment characteristics are improved, but the overall size increases
Solution Approach 1:
The turned flange extends the attachment rim into the vertical dimension, providing adequate reinforcement area and improved attachment characteristics without increasing the horizontal footprint. The vertical extension of the flange portion allows for proper fastener engagement and structural reinforcement while maintaining a compact overall package size.
Solution Approach 2:
The turned flange concentrates the reinforcement and attachment functionality at specific localized regions where fasteners are needed, rather than uniformly extending the entire attachment rim. This localized quality approach provides adequate reinforcement where required while minimizing the overall size increase.
3Area of stationary object
If the attachment rim is kept compact, then packaging efficiency is improved, but structural integrity deteriorates due to inconsistent fiber distribution
Solution Approach 1:
By extending the attachment rim vertically through the turned flange rather than horizontally, the design maintains a compact packaging footprint while achieving adequate structural integrity. The vertical flange portion provides the necessary reinforcement and fiber distribution area without increasing the horizontal packaging area.
4Reliability
If the attachment rim extends outward to compensate for fiber distribution, then fastening reliability is improved, but device complexity increases
Solution Approach 1:
The turned flange structure segments the attachment rim into distinct functional portions: a horizontal platform portion for fastener positioning and a vertical flange portion for structural reinforcement and fiber distribution. This segmentation allows each portion to optimize its specific function while maintaining overall fastening reliability without excessive complexity.
Data Source
AI summary
A traction battery pack assembly includes, among other things, first and second pieces of an enclosure having an interior area. An attachment rim is disposed at a periphery of the first piece. The attachment rim has a stand-off that includes a platform portion and turned flange. The platform portion extends outward from the interior area in a first direction. The platform portion provides an aperture. The turned flange extends away from the platform portion in a second direction and terminates at an end face. The second direction is transverse to the first direction. The aperture is configured to receive a fastener that clamps the end face against the second piece.