Battery Pack Assembly Using Vacuum-Compressed Foam Preload
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for assembling battery packs face difficulties in applying a pre-tightening force to battery modules while maintaining efficient assembly and reducing the volume of the battery pack, leading to increased space occupation and reduced practicality.
Innovation Solution
The method involves loading a battery module with foam into an insulating bag, vacuumizing the bag to compress the foam, allowing for easier assembly into a box, and then releasing the vacuum to restore the foam's original shape, enabling zero-clearance assembly and effective pre-tightening of the battery module within the box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the size of the box is designed to be comparable to the size of the battery module to apply pre-tightening force, then the pre-tightening force is improved, but the assembly difficulty increases and manual insertion becomes very difficult
Solution Approach 1:
The foam inside the battery module is compressed in advance by vacuumizing the insulating bag before assembly, reducing the module's volume to facilitate easy insertion into the box. After assembly, the vacuum state is released and the foam restores its original volume, automatically applying pre-tightening force to the battery module.
Solution Approach 2:
A vacuum pump is used to create a vacuum state inside the insulating bag, which compresses the foam material. This pneumatic approach enables volume reduction for easy assembly and subsequent automatic pre-tightening force application without mechanical intervention.
2Force
If a mechanical tool is used to apply mechanical force for assembly, then the pre-tightening force is improved, but the risk of damage to the box or battery module increases and assembly efficiency decreases
Solution Approach 1:
The foam material serves a dual function: it acts as a cushioning element during assembly and then automatically restores its volume after vacuum release to apply pre-tightening force. This self-service mechanism eliminates the need for external mechanical tools, preventing damage while maintaining reliability.
Solution Approach 2:
The mechanical force application system is replaced with a pneumatic-volumetric system. Instead of using mechanical tools to apply force, the patent uses vacuum compression and elastic restoration of foam to achieve both assembly facilitation and pre-tightening force application, eliminating mechanical damage risks.
3Ease of operation
If the size of the box is set to be much larger than the battery module to facilitate assembly, then the assembly ease is improved, but the volume utilization rate decreases and the battery pack occupies more space
Solution Approach 1:
The foam is compressed in advance through vacuumization, reducing the battery module's volume to fit tightly within the box during assembly. This preliminary volume reduction enables easy assembly without requiring excessive box size, and the subsequent foam restoration achieves zero-clearance assembly for optimal space utilization.
Solution Approach 2:
The volume parameter of the battery module is dynamically changed through vacuum compression during assembly and then restored after assembly. This parameter change allows the module to be compact during insertion and then expand to fill the box completely, achieving both easy assembly and high volume utilization rate.
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
This approach improves assembly efficiency, reduces the volume of the battery pack, enhances the volume utilization rate, and ensures a stable pre-tightening force, making the battery pack more practical and space-efficient for vehicle integration.
Implementation Method 1
vacuumizing the insulating bag, thus reducing the volume of the entire battery module
Implementation Method 2
the foam can utilize the high resilience thereof to restore an original volume of the battery module
Data Source
AI summary
Provided are a battery pack using a method for assembling a battery pack and a vehicle. The battery pack includes a box and battery modules. The box is provided with cavities inside. The battery module includes foam and multiple cells. The foam is arranged between adjacent cells. The method for assembling a battery pack includes the following steps: the battery module is loaded into an insulating bag; the insulating bag is vacuumized so that the foam is compressed to reduce the volume of the battery module; and after the battery module of the reduced volume is inserted into the cavity, a vacuum state is released and positive and negative electrodes of the battery module are exposed.