Battery Pack Cell Carrier Alignment With Integrated Thermal Datum
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Solution Overview
Problem
Existing battery systems for electric vehicles face challenges in efficient thermal management and assembly precision, leading to manufacturing inefficiencies and increased costs due to reliance on external datum strategies and complex assembly processes.
Innovation Solution
A battery system design that aligns a first cell carrier with a thermal component and a second cell carrier using internal part-to-part datums and locating features, eliminating the need for external datum references and allowing the system to absorb compression loads through deformable ribs, thereby simplifying the assembly process and improving manufacturing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If external datum strategies are used for assembly alignment, then assembly precision can be maintained, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent integrates the thermal management component with the battery assembly structure by incorporating alignment features (datums and locating features) directly into the thermal component itself. This merging eliminates the need for separate external datum references and complex alignment procedures, while maintaining precise assembly alignment between battery cells and thermal management elements.
2Manufacturing precision
If complex assembly processes are used to ensure proper alignment, then assembly precision is improved, but productivity decreases
Solution Approach 1:
The thermal management component is designed with self-aligning features where datums and locating features are integrated directly into its structure. This self-service alignment mechanism automatically guides proper positioning during assembly without requiring complex external alignment procedures, thereby maintaining precision while accelerating the assembly process and improving productivity.
3Temperature
If thermal management is integrated into the battery system, then thermal management efficiency is improved, but assembly complexity increases
Solution Approach 1:
The patent combines the thermal management function with the battery assembly structure by integrating cooling plates or thermal management elements directly into the battery pack architecture. The alignment features (datums and locating features) are incorporated into this integrated structure, enabling precise positioning without requiring separate complex assembly procedures, thus improving thermal efficiency while avoiding increased assembly complexity.
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
This design enhances manufacturing efficiency, reduces assembly variations, and decreases scrap costs by integrating thermal management directly into the battery system assembly, improving the overall production process and system performance.
Implementation Method 1
the protruding rib can at least partially deform to absorb a compression load between the first cell carrier, the second cell carrier, and the thermal component
Data Source
AI summary
A battery system can include a first cell carrier having a first datum. The first datum of the first cell carrier can align with a second datum of a thermal component and at least partially receive a locating feature of a second cell carrier.