Battery Pack Separator With Hook Projections For Cell Stability
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Solution Overview
Problem
Battery cells in electric vehicle battery packs tend to shift relative to other components during installation and shipping, leading to instability and potential isolation faults.
Innovation Solution
The use of a separator with projections and restraint tabs that limit upward and lateral movement of battery cells by engaging with the array structure's side walls and cold plate, ensuring secure positioning and thermal contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery cells are arranged in an array structure, then energy storage capacity is improved, but cells tend to shift relative to other components during installation and shipping
Solution Approach 1:
A separator is introduced as an intermediary component between adjacent battery cells. The separator includes a spacer section positioned between the cells and restraint tabs that extend to engage with the cells, preventing their relative movement while maintaining the array structure's energy storage capacity.
Solution Approach 2:
The separator is divided into distinct functional segments: a spacer section that maintains spacing between cells and restraint tabs that actively prevent movement. This segmentation allows each part to perform its specific function in stabilizing the array structure.
2Stability of the object's composition
If separator is added to secure battery cells, then cell stability is improved, but device complexity increases
Solution Approach 1:
The separator merges multiple functions into a single component: it provides spacing between cells through the spacer section, prevents movement through restraint tabs, and facilitates coolant flow through integrated channels. This consolidation reduces the number of separate components needed.
Solution Approach 2:
The separator is designed as a multi-functional component that simultaneously performs mechanical restraint, spacing maintenance, and thermal management functions, making it a universal solution for multiple problems in the battery array.
3Manufacturing precision
If restraint tabs are used to limit cell movement, then cell positioning is improved, but manufacturing complexity increases
Solution Approach 1:
The restraint tabs are pre-formed as integral parts of the separator during its manufacturing process. This preliminary formation of the restraint features eliminates the need for separate attachment steps, simplifying the overall manufacturing process while ensuring precise cell positioning.
Data Source
AI summary
An exemplary method of securing battery cells of a battery pack includes limiting upward movement of a separator by blocking movement of a projection with a structure. The projection extends from a spacer section of the separator and has a hook shape with an upwardly extending portion outside the structure. The method further includes limiting upward movement of a battery cell using the separator. Another exemplary method of securing battery cells of a battery pack includes limiting movement of a separator in a direction by blocking movement of a projection in the direction. The projection extends from a spacer section of the separator. The projection has a hook shape with a portion extending in the direction. The spacer section and the portion are on opposite sides of a structure. The method further includes limiting movement of a battery cell in the direction using the separator.