Compressed Cell Fixture for Battery Vibration Damping
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Solution Overview
Problem
High-voltage battery cells in motor vehicles experience vibration-induced fatigue and rattling noises due to dimensional tolerances, making it challenging to fix them securely using simple mechanical means, which can lead to reduced service life and complex, costly constructions.
Innovation Solution
A method using a cell block configuration with a first and second cell carrier holding cells in a sandwich-like fashion, where a compressible cell fixture is inserted between them, allowing for even and firm fixation regardless of tolerances, reducing the need for precise adaptation and individual clamping, and utilizing a non-conductive, elastic foam or material for the cell fixture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If simple mechanical means are used to fix cells, then device complexity is reduced, but manufacturing precision deteriorates due to dimensional tolerances
Solution Approach 1:
The cell fixture is compressed in the Z-direction (main extension direction of elongated cells) which causes the material to expand along spatial directions X and Y perpendicular to the compression direction. This parameter change in volume and shape allows the fixture to adapt to dimensional tolerances of cells, achieving precise positioning without complex mechanical adjustment mechanisms.
Solution Approach 2:
The cell fixture is made of elastic material that can be compressed and deformed. When compressed between the two cell carriers, the flexible material expands laterally to enclose each cell evenly, accommodating dimensional variations. This flexible approach replaces rigid, precision-machined mechanical fixtures with a compliant material-based solution.
2Manufacturing precision
If precise adaptation mechanisms are used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The cell fixture automatically adapts to cell dimensional tolerances through its own elastic deformation when compressed. The material itself performs the adaptation function without requiring external adjustment mechanisms, sensors, or control systems. Each cell is enclosed evenly by the expanding material, achieving precise fixation through self-adjustment.
3Manufacturing precision
If individual clamping is used for each cell, then manufacturing precision is improved, but device complexity and quantity of parts increase
Solution Approach 1:
Multiple individual cell clamping functions are merged into a single continuous cell fixture made of elastic material. When compressed, the fixture expands to enclose multiple cells simultaneously, providing individual positioning for each cell through the continuous material surface. This eliminates the need for separate clamping mechanisms for each cell, reducing part quantity while maintaining positioning precision.
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 effectively reduces vibrations and rattling noises, extends the service life of the battery, allows for easy adaptation to varying cell geometries, and simplifies the construction process by compensating for tolerances with minimal parts, while enabling easy disassembly and reducing material costs.
Implementation Method 1
If the direction of compression is the Z-direction, which, in the case of elongated cells, is their main direction of extension, the material of the cell fixture expands along spatial directions X and Y, which are perpendicular to the Z direction.
Implementation Method 2
the cell fixture includes a material that can be compressed and is elastic, but is at least softer than the cell carrier
Data Source
AI summary
A method for fixing battery cells includes positioning each battery cell in a respective opening of a cell fixture; inserting a first side of each battery cell into a respective opening of a first cell carrier; inserting a second side, opposite to the first side, of each battery cell into a respective opening of a second cell carrier, such that the cell fixture is positioned between the first and second cell carriers; and pressing the first and second cell carriers together to compress the cell fixture.