Battery Pack Cell Holder With Integrated Casing Alignment
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Solution Overview
Problem
Existing battery packs require a separate spacer for proper alignment of the cell holder and casing, increasing manufacturing complexity and steps, and lacking an integrated solution for easy positioning.
Innovation Solution
The battery pack design incorporates a cell holder with convex extension portions that abut the casing's inner wall, eliminating the need for a separate spacer and simplifying assembly by ensuring easy alignment and integration during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate spacer is inserted between the cell holder and casing to maintain positioning, then the positioning accuracy is improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The spacer function is merged with the cell holder by forming a convex extension portion directly on the cell holder body. This integration eliminates the need for a separate spacer component while maintaining the positioning function, thereby reducing device complexity and manufacturing steps.
Solution Approach 2:
The cell holder is segmented into a main body portion and a convex extension portion. The convex extension portion is specifically designed to protrude and contact the casing inner wall, providing precise positioning without requiring additional components.
2Manufacturing precision
If a separate spacer is used to bridge the gap between cell holder and casing, then the positioning is improved, but the manufacturing operation becomes more complicated
Solution Approach 1:
The spacer functionality is combined with the cell holder structure through integral formation of the convex extension portion. This eliminates the need for separate spacer production and joining operations, significantly simplifying the manufacturing process.
Solution Approach 2:
The cell holder's convex extension portion automatically provides the spacing and positioning function without requiring external spacer components. The structure serves itself by incorporating the positioning feature directly into its design.
3Shape
If the casing side surface is curved to bulge for aesthetic improvement, then the appearance is enhanced, but a gap is formed between cell holder and casing making positioning difficult
Solution Approach 1:
The casing side surface is designed with a curved, bulging shape to improve appearance. The convex extension portion of the cell holder is correspondingly designed to protrude and contact the curved inner wall, ensuring proper positioning despite the non-linear geometry.
Solution Approach 2:
The convex extension portion is specifically designed with localized geometry to match the curved casing profile at the contact point. This local adaptation ensures precise positioning while maintaining the overall aesthetic curvature of the casing.
Data Source
AI summary
A battery pack is provided with a cell holder including a holder main body portion, and a casing accommodating the cell holder. The holder main body portion holds a plurality of unit cells. Protruding extended portions projecting toward an inner wall of the casing are provided on an outer wall of the holder main body portion. The protruding extended portions include abutting extended portions which abut the inner wall of the casing.