Battery Output Pole Base Metal Insert for Vibration-Resistant Fixing
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Solution Overview
Problem
The existing battery module design fails to achieve complete fixation between the output pole base and the end plate, leading to vibration-induced fractures and reduced connection reliability, causing the battery module to malfunction.
Innovation Solution
Incorporating a metal matching part connected to the output pole base, which provides an interference fit or hardness difference with the end plate, ensuring secure attachment and reducing relative movement during vibrations, thereby enhancing connection reliability and service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a processing groove and bump contour complementary matching connection is used between the end plate and output pole base, then the structure is simple and easy to manufacture, but the connection is not complete and gaps remain between components
Solution Approach 1:
The patent applies composite materials by combining metal matching part with plastic output pole base, creating a hybrid structure that leverages the strength and rigidity of metal for the matching part while maintaining the insulation and ease of manufacturing of plastic for the base structure. This composite approach resolves the contradiction by achieving both manufacturability and reliable connection.
Solution Approach 2:
The matching part is nested within the output pole base structure, with the metal matching part inserted into the plastic base. This nesting arrangement allows the simpler plastic base to contain the more complex metal connection element, achieving complete fixation while maintaining manufacturing efficiency through modular assembly.
2Device complexity
If the output pole base is fixed with the end plate using contour complementary matching, then the device complexity is low, but the output pole base cannot be completely fixed and vibrates under vibration conditions
Solution Approach 1:
By introducing a metal matching part into the plastic output pole base, the patent creates a composite structure that significantly improves vibration resistance and stability. The metal component provides rigid fixation with the end plate while the plastic base maintains structural integrity, resolving the contradiction between low device complexity and high stability.
Solution Approach 2:
The patent applies local quality by making only the matching part (local region) from metal material while keeping the rest of the output pole base from plastic. This localized material differentiation provides enhanced stability and vibration resistance at the critical connection point without unnecessarily complicating the entire device structure.
3Reliability
If a metal matching part with interference fit or hardness difference is used to connect the output pole base and end plate, then the connection reliability and stability are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The nested structure allows the metal matching part to be inserted into the pre-formed plastic output pole base, enabling sequential manufacturing that maintains ease of production. The plastic base can be molded first, then the metal matching part is inserted and fixed, achieving reliable interference fit connection without requiring complex simultaneous manufacturing processes.
Solution Approach 2:
The patent segments the output pole base into two distinct components: the plastic base structure and the metal matching part. This segmentation allows each component to be manufactured separately using optimal processes for each material, then assembled together. The simple geometric shapes of both components facilitate easy manufacturing while the interference fit design ensures high connection reliability.
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
The solution achieves complete fixing between the output pole base and the end plate, reducing the risk of fractures and improving the connection reliability between the output pole connecting piece and the unit battery pole column, thus prolonging the battery module's service life and preventing gaps from forming during long-term operation.
Implementation Method 1
the matching part and the end plate have an interference fit
Implementation Method 2
the matching part and the end plate have a hardness difference, so that the matching part can penetrate into the end plate or a portion of the end plate can penetrate into the matching part
Data Source
AI summary
A battery module and a vehicle. The battery module includes: a unit battery; an end plate located at an end of the battery module along a length direction; and an output pole base including a mounting part and a matching part which are fixedly connected, where the matching part is made of metal material and is fixedly connected to the end plate to limit the freedom degree of movement of the output pole base relative to the end plate along the height direction, the width direction and the length direction. The plastic structure of the output pole base is added a matching part made of metal material therein and is fixedly connected to the end plate by the matching part.