Battery Module Bracket With Elastic Positioning for Tool-Free Cell Assembly
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Solution Overview
Problem
The assembly of battery modules is inefficient due to the need for a positioning tool to remain until structural adhesive cures, limiting mass production efficiency and increasing the risk of cell misalignment and welding failures.
Innovation Solution
A bracket with placement grooves and elastic positioning devices that allow cells to be directly loaded and positioned without a tool, maintaining stability during adhesive curing and use, thereby simplifying assembly and extending the battery module's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a positioning tool is used to load and position cells during assembly, then manufacturing precision is improved, but device complexity and productivity are worsened due to the need to retain the tool until adhesive curing
Solution Approach 1:
The positioning function is segmented from the temporary positioning tool and integrated into the bracket structure itself through multiple positioning devices with elastic structures. Each positioning device independently provides positioning force to cells at different locations, enabling the bracket to perform both structural support and positioning functions simultaneously, thus eliminating the need to retain the positioning tool during adhesive curing.
Solution Approach 2:
The bracket structure provides self-positioning capability through integrated positioning devices with elastic structures that automatically exert positioning force on cells. The elastic structures deform under cell insertion and provide continuous positioning pressure without requiring external tools or additional fixing mechanisms, enabling the assembly to self-maintain cell positions during adhesive curing.
2Reliability
If a positioning tool is retained until adhesive curing to prevent cell shift, then reliability is improved, but loss of time increases due to inability to remove the tool
Solution Approach 1:
The positioning devices with elastic structures are pre-installed on the bracket before cell assembly. When cells are inserted, the elastic structures automatically deform and exert positioning force immediately, providing continuous position stability throughout the adhesive curing process without requiring temporary tools to be retained, thus eliminating the time loss associated with tool retention.
Solution Approach 2:
The elastic structures serve as intermediary elements between the rigid bracket and the cells, providing flexible positioning force that adapts to cell insertion while maintaining stable cell positions during adhesive curing. The elastic deformation allows the positioning devices to continuously exert gentle pressure on cells, ensuring position stability without requiring mechanical constraints from external tools.
3Manufacturing precision
If multiple positioning devices with elastic structures surround each cell, then manufacturing precision and reliability are improved, but device complexity increases
Solution Approach 1:
The positioning devices with elastic structures perform multiple functions: they provide positioning force to cells, accommodate cell insertion through elastic deformation, and maintain continuous contact pressure during adhesive curing. This multi-functionality eliminates the need for separate positioning tools and additional fixing mechanisms, reducing overall system complexity while improving positioning accuracy through the surrounding array of positioning devices.
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 enhances assembly efficiency, reduces the risk of misalignment and welding failures, and extends the service life of the battery module by maintaining cell stability during adhesive curing and use.
Implementation Method 1
each of the positioning devices includes one or more elastic structures, and each of the elastic structures is configured to abut against an outer periphery of one of the cells
Data Source
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AI summary
A bracket is applicable to a battery module including multiple cells. The bracket includes a base and multiple positioning devices. The base is provided with multiple placement grooves spaced apart from each other and arranged in an array, and has multiple arrangement areas spaced apart from each other. Each of the placement grooves has an outer periphery surrounded by ones of the arrangement areas, and the cells are capable of being inserted respectively into the plurality of placement grooves. The positioning devices are arranged respectively in the arrangement areas. Each of the positioning devices includes one or more elastic structures, and each of the elastic structures is configured to abut against an outer periphery of one of the cells.