Battery Cell Stack Coupling for Damage-Free Housing Insertion
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Solution Overview
Problem
Existing methods for inserting battery cell packages into motor vehicle battery modules often result in incomplete insertion or damage to deflector tabs due to pressure loads, particularly on the insertion back side, which can lead to incomplete insertion or damage to the battery cell package.
Innovation Solution
The solution involves forming drive coupling structures like elevations, indentations, or knobs on the battery cell package's outer sides and using insertion auxiliary layers, such as guide rails, which can be connected separately and feature a predetermined breaking point, along with a drive roller with extendable roller coupling structures to ensure secure and damage-free insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If pressure load is applied on the insertion back side to insert the battery cell package, then insertion force is provided, but the battery cell package or deflector tab may become damaged
Solution Approach 1:
A drive roller with roller coupling structures serves as an intermediary between the insertion mechanism and the battery cell package. The roller coupling structures engage with coupling structures on the battery cell package, enabling force transmission without direct pressure contact that could cause damage to deflector tabs or the package itself.
Solution Approach 2:
The drive roller is designed with extendable roller coupling structures that can dynamically adjust their position. This allows the coupling structures to engage with the battery cell package at optimal points, providing insertion force while avoiding contact with vulnerable components like deflector tabs.
2Ease of operation
If cylindrical rollers are used to compress and insert the battery cell package, then insertion is achieved, but incomplete insertion or damage may occur
Solution Approach 1:
The drive roller incorporates extendable roller coupling structures that can dynamically adjust during the insertion process. This dynamic adjustment ensures reliable engagement with the battery cell package coupling structures, preventing incomplete insertion while avoiding damage through controlled force application.
Solution Approach 2:
The insertion system changes the parameter of force application by using form-fitting coupling structures instead of uniform compression. The roller coupling structures are designed to engage specifically with complementary coupling structures on the battery cell package, transforming the insertion mechanism from general compression to targeted, controlled movement that ensures complete and damage-free insertion.
3Adaptability or versatility
If deflector tabs protrude from the battery cell package, then structural function is provided, but vulnerability to damage during insertion increases
Solution Approach 1:
The drive roller with roller coupling structures acts as an intermediary that bypasses the deflector tabs during force transmission. The coupling structures are designed to engage with the battery cell package at locations that do not involve the deflector tabs, allowing these tabs to maintain their structural function while avoiding exposure to insertion forces that could cause damage.
Data Source
AI summary
A battery cell for a motor vehicle, having a battery cell housing having an insertion opening and at least one cell stack to be inserted into the battery cell housing, and drive coupling structures in the form of elevations and/or indentations extending transversely to the insertion direction being formed on at least one outer side of the cell stack. A system is also provided for a mounting device with at least one drive roller for inserting a cell stack into a battery cell housing of a battery cell. The drive roller having roller coupling structures distributed over the circumference, which are designed to be complementary to the coupling structures on the battery cell package. Also, a method for inserting a cell stack is provided.