Battery Retention Assembly Using Polyester Strap and Carabiner
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Solution Overview
Problem
High voltage batteries in vehicles require effective structural support to manage cell expansion, temperature, and electrical isolation, while existing solutions often fail to provide adequate compression and tensile load capabilities.
Innovation Solution
A traction battery assembly featuring endplates with receiving grooves, a nonconductive strap made of polyester filament yarn, and an attachment fitting with a carabiner, which compresses the battery cells and applies tension, ensuring electrical isolation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing structural support solutions are used, then some level of cell retention is achieved, but adequate compression and tensile load capabilities are not provided
Solution Approach 1:
The retention assembly is divided into distinct functional components: endplates that apply compression, straps that provide tensile restraint, and attachment fittings that connect the components. This segmentation allows each component to be optimized for its specific function, enabling the assembly to provide both adequate compression and tensile load capabilities while effectively managing cell expansion
Solution Approach 2:
The strap is constructed from polyester filament yarn, creating a composite material structure that provides high tensile strength while maintaining flexibility. This composite approach allows the strap to effectively restrain cell expansion in the tensile direction while working in conjunction with the endplates for compression management
2Reliability
If conventional retention methods are used, then basic structural support is provided, but electrical isolation of battery cells is not ensured
Solution Approach 1:
The strap is made from nonconductive polyester filament yarn, creating a homogeneous nonconductive barrier between battery cells. This homogeneous material selection ensures electrical isolation throughout the entire strap structure, preventing electrical contact between cells while maintaining structural support functionality
Solution Approach 2:
The nonconductive polyester strap acts as an intermediary element between battery cells, providing both mechanical restraint and electrical isolation. This intermediary function allows the strap to mediate between the need for structural support and the need for electrical isolation without requiring additional separate components
3Reliability
If complex attachment systems are used, then secure connection is achieved, but installation and handling become difficult
Solution Approach 1:
The attachment fitting incorporates a dynamic locking mechanism that allows for easy engagement and disengagement during installation and maintenance, while providing secure, reliable connection when installed. The dynamic nature of the attachment system enables simple handling during assembly while ensuring robust connection during operation
Solution Approach 2:
The attachment fitting is designed to self-secure through its locking mechanism, eliminating the need for complex tools or multiple fastening steps during installation. The self-service design allows the fitting to automatically secure the strap to the endplates, simplifying installation while maintaining connection security
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 provides reliable compression and tensile load management, preventing cell bulging, simplifying installation and handling, while maintaining electrical isolation and structural integrity.
Implementation Method 1
a gate pivotally secured to one of the distal ends. The gate may be configured to engage the other of the distal ends
Implementation Method 2
The strap may be of a nonconductive material to electrically isolate the battery cells
Implementation Method 3
the endplates compress the cells
Implementation Method 4
The strap may be of a material having a tensile load capability in excess of a predetermined expansion load of the cells
Data Source
AI summary
A traction battery assembly is provided. The traction battery assembly may include an array of battery cells, a pair of endplates, a strap, and an attachment fitting. Each of the pair of endplates may be disposed on opposite ends of the array and define edges and a receiving groove extending between the edges. The strap may be sized to sit within the groove and wrap around the array and endplates. The attachment fitting may connect ends of the strap such that the endplates compress the cells. The endplates may each further define the receiving groove at a mid-region of the endplates such that the strap wraps around the array at a substantially middle portion of outer faces defined by the array.