Battery Cell Stack Retention Interfaces for Stable Compression Load
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Solution Overview
Problem
Existing traction battery packs face challenges in securely connecting cross-member assemblies and compression end plates, which affects the structural integrity and efficiency of the battery pack.
Innovation Solution
The proposed traction battery pack design includes a first cross-member assembly with a ladder frame and a compression end plate, both featuring retention features that engage to secure the compression end plate to the cross-member assembly, ensuring a stable and compressive load across the cell stack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional connection methods are used between cross-member assemblies and compression end plates, then the manufacturing process is simple, but the structural integrity and connection strength are insufficient
Solution Approach 1:
The connection system is divided into separate male and female retention features. The female retention feature is integrated into the cross-member assembly while the male retention feature is integrated into the compression end plate, creating modular, interchangeable connection components that improve strength while maintaining manufacturing simplicity
Solution Approach 2:
The retention features are merged with the structural components themselves rather than being separate fasteners. The female retention feature becomes part of the cross-member assembly and the male retention feature becomes part of the compression end plate, eliminating the need for additional connection hardware and reducing overall device complexity
2Reliability
If retention features are added to secure cross-member assemblies and compression end plates, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The retention features are pre-formed as integral parts of the cross-member assembly and compression end plate during their respective manufacturing processes. The female retention feature is molded into the cross-member assembly and the male retention feature is molded into the compression end plate, eliminating the need for post-assembly operations and maintaining manufacturing ease
Solution Approach 2:
The cross-member assembly utilizes a composite structure combining a thermoplastic ladder frame with pultruded reinforcement beams. This composite construction provides the necessary structural integrity and rigidity to support the retention features while maintaining ease of manufacturing through established composite fabrication processes
3Stability of the object's composition
If a secure connection between cross-member assemblies and compression end plates is implemented, then the compression load stability is improved, but the device complexity increases
Solution Approach 1:
The retention features are designed to self-align and self-engage during assembly. The male retention feature with protrusion automatically engages with the corresponding female retention feature with recess, providing stable compression load without requiring complex alignment mechanisms or additional fastening operations
Solution Approach 2:
The retention features serve multiple functions: they provide structural connection between components, ensure proper alignment during assembly, and maintain stable compression loads on the battery cell stack. This multi-functionality reduces the need for separate components and simplifies the overall device complexity
Data Source
AI summary
Battery cell stack designs are provided for traction battery packs. An exemplary cell stack may include a cross-member assembly and a compression end plate that may be secured together at one or more mating connections for maintaining the cell stack together before a future assembly into a full traction battery pack. The compression end plates may tie into the cross-member assemblies via one or more mateable retention features for establishing the mating connections and allowing the compression end plates to apply a compressive load across the cell stack. Subsequently, a structural megabar may be mounted to the cross-member assembly for further structurally integrating the traction battery pack.