Cell Stack Interlocking Assembly for Faster Thermal Barrier Bonding
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Solution Overview
Problem
The existing manufacturing processes for traction battery packs face challenges in reducing cell stack assembly times, which affects the overall efficiency and speed of production.
Innovation Solution
The proposed solution involves an interlocking assembly within the cell stack of the traction battery pack, comprising a crossmember frame, a structural thermal barrier, an adhesive, and a rod. The rod secures the structural thermal barrier to the crossmember frame while the adhesive cures, allowing for faster assembly without the need for fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional adhesive bonding is used to attach thermal barriers to crossmember frames, then bonding strength is achieved, but assembly time is excessive due to required fixture holding and extended curing periods
Solution Approach 1:
The patent applies preliminary action by pre-positioning the thermal barrier within the crossmember frame using a retaining structure (such as a retaining tab or groove) before adhesive application. This preliminary mechanical retention eliminates the need for external fixtures during curing, allowing immediate removal from the assembly line while the adhesive cures independently, thus reducing assembly time without compromising bonding strength
Solution Approach 2:
The patent introduces an intermediary retaining structure (such as a retaining tab on the thermal barrier or a groove in the crossmember frame) that acts as a temporary mediator to hold the thermal barrier in place during adhesive curing. This intermediary mechanism provides mechanical retention without requiring external fixtures, enabling faster assembly while ensuring proper positioning until the adhesive achieves sufficient strength
2Manufacturing precision
If fixtures are used to hold thermal barriers during adhesive curing, then positioning accuracy is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the positioning and retention functions into the thermal barrier and crossmember frame themselves through integrated features such as retaining tabs, grooves, or recesses. This consolidation eliminates the need for separate external fixtures, maintaining positioning accuracy while reducing device complexity and manufacturing cost by incorporating the retention mechanism directly into the bonded components
3Strength
If extended adhesive curing time is allowed, then bond strength is maximized, but production throughput is reduced
Solution Approach 1:
The patent applies preliminary action by implementing mechanical retention (through retaining tabs, grooves, or interlocking features) before adhesive curing begins. This preliminary mechanical support allows the adhesive to cure without requiring extended time or external fixtures, enabling the assembly to be removed from the production line at optimal cure points while maintaining bond strength, thus improving production throughput
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 solution enables faster assembly of cell stacks by holding the structural thermal barriers in place with rods during adhesive curing, thereby increasing manufacturing efficiency and reducing assembly time.
Implementation Method 1
an adhesive layer positioned between the crossmember frame and the structural thermal barrier
Data Source
AI summary
Interlocking assemblies are provided for use within cell stacks of a traction battery pack. An exemplary interlocking assembly may include a crossmember frame, a structural thermal barrier, an adhesive, and a rod. The adhesive may be disposed between the crossmember frame and the structural thermal barrier. The rod may then be inserted through the crossmember frame and the structural thermal barrier for retaining the structural thermal barrier to the crossmember frame while the adhesive cures.