Battery Cell Stack Drive Coupling for Safe Housing Insertion
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Solution Overview
Problem
Existing methods for inserting battery cell packs into motor vehicle battery cell housings risk damaging the cell stack due to pressure on arrester flags or other protruding elements, leading to incomplete insertion or damage during the insertion process.
Innovation Solution
The solution involves forming drive coupling structures such as elevations, depressions, or guide rails on the battery cell pack, which interact with complementary roller structures on a drive roller to facilitate safe and complete insertion, with optional features like elongated holes for tolerance compensation and a predetermined breaking point for guide rail removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If compression is applied to the battery cell pack during insertion, then insertion force is sufficient to push the cell stack into the housing, but the arrester flags or protruding elements may be damaged by pressure on the back of the insert
Solution Approach 1:
The patent introduces a compression element as an intermediary component between the drive roller and the battery cell pack. This compression element applies compressive force to the cell stack through its front side while its rear side prevents direct pressure on the arrester flags, thereby mediating the insertion process without causing damage to protruding elements
Solution Approach 2:
The compression element is designed with segmented functionality: a front side for applying compression force to the cell stack, a rear side for protecting arrester flags, and optional coupling structures for interaction with the drive roller. This segmentation allows each part to perform its specific function without interfering with other components
2Device complexity
If the battery cell pack is inserted without coupling structures, then the structure is simpler, but the insertion process cannot safely protect protruding elements from damage
Solution Approach 1:
The compression element serves as a mediator that incorporates coupling structures to interact with the drive roller, enabling controlled insertion while protecting the battery cell pack components. This intermediary approach maintains reasonable structural complexity while ensuring reliable and safe insertion
Solution Approach 2:
The compression element is designed with coupling structures that engage with the drive roller before the insertion process begins, establishing a controlled mechanism that prevents damage to protruding elements throughout the subsequent insertion process
3Manufacturing precision
If compression is applied to ensure complete insertion, then the cell stack is fully inserted into the housing, but further insertion risks damaging the battery cell pack or protruding elements
Solution Approach 1:
The compression element acts as a protective intermediary that transmits compression force to achieve complete insertion while preventing direct contact between the drive roller and the battery cell pack, thereby eliminating the risk of damage during the insertion process
Solution Approach 2:
The compression element provides beforehand cushioning by positioning itself between the drive roller and the battery cell pack, absorbing and distributing insertion forces in a controlled manner that prevents damage to the cell stack and protruding elements during complete insertion
Data Source
Figure 1~2
Figure 2
Figure 3~4b
AI summary
The invention relates to a battery cell for a motor vehicle, comprising a battery cell housing (12) with an insertion opening (14) and at least one cell stack (16) to be inserted into the battery cell housing (12), wherein drive coupling structures (28) in the form of elevations and/or depressions (30) extending transversely to the insertion direction are formed on at least one outer surface (18, 20) of the cell stack (16). The invention further relates to a system comprising an assembly device (40) with at least one drive roller (38) for inserting a cell stack (16) into a battery cell housing (12) of a battery cell (10) according to one of the preceding claims, wherein the drive roller (38) has roller coupling structures (34) distributed around its circumference, which are complementary to the coupling structures (28) on the battery cell pack (16), and a method for inserting a cell stack (16).