Battery Pack Cell Carrier Snap-Fit Coupling for Electrical Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The construction of battery packs for electric vehicles is complicated by the need for additional fasteners and insulative materials due to the close proximity of high voltage components, which increases complexity and potential for errors.
Innovation Solution
A Battery Voltage and Temperature module (BVT) that uses a 2-way and 4-way locating scheme with pins and snap-fit clips to interface with a battery tote, eliminating the need for additional fasteners by coupling with a cell carrier through specific engagement features and interfacing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fasteners and insulative materials are used to couple components near high voltage components, then reliability and electrical isolation are improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The housing integrates multiple functions into a single component: it provides structural support, electrical isolation through insulative material, and mechanical coupling through integrated engagement features. This eliminates the need for separate fasteners and insulative materials, reducing assembly complexity while maintaining reliability
Solution Approach 2:
The housing serves multiple purposes simultaneously: it protects internal components, provides electrical isolation from high voltage components, and couples the module to the battery subassembly through integrated engagement features. This multi-functionality reduces the number of separate components needed
2Reliability
If additional fasteners and insulative materials are used to couple components near high voltage components, then reliability and electrical isolation are improved, but manufacturing complexity and potential for errors increase
Solution Approach 1:
The housing combines structural support, electrical isolation, and mechanical coupling functions into one integrated component. This eliminates multiple separate parts that would need to be assembled, making manufacturing and assembly easier while maintaining electrical isolation reliability
Solution Approach 2:
The engagement features are extracted and integrated directly into the housing structure, eliminating the need for separate fasteners. This simplifies the manufacturing process by reducing the number of components that need to be sourced, assembled, and inspected
3Adaptability or versatility
If numerous components are coupled separately, then adaptability and modular construction are improved, but device complexity and assembly time increase
Solution Approach 1:
The housing merges multiple functional components into a single integrated unit that maintains modular adaptability. The engagement features allow the housing to interface with different battery subassembly configurations while reducing the total number of separate components needed
Data Source
AI summary
An apparatus can include a cell carrier that defines a first engagement feature and a second engagement feature. The first engagement feature and the second engagement feature can be configured to engage with a housing. The cell carrier can be configured to couple with the housing via at least one of the first engagement feature or the second engagement feature.