Elastomer Cylinder Battery Holder for Vibration Damping
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Solution Overview
Problem
The existing car power source battery apparatuses face challenges in manufacturing complexity and high costs due to the need for precise openings for battery modules, which are difficult to achieve with variations in battery diameters, leading to instability and labor-intensive assembly. Additionally, they struggle to securely hold battery modules with non-straight connections and provide adequate cooling.
Innovation Solution
The solution involves a holder case with elastomer cylinders that cover battery connections and provide flexible support, allowing for secure retention of battery modules with varying diameters and non-straight connections, while also establishing cooling gaps for efficient ventilation. This design eliminates the need for ribs projecting from the inner surfaces and simplifies assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If openings are formed in both end planes and intermediate planes to hold battery modules, then battery modules can be retained in specified positions, but the holder case requires complex mold structure and high manufacturing cost
Solution Approach 1:
The holder case is divided into an upper holder and a lower holder that are assembled together, allowing each part to be manufactured separately with simpler molds. The battery modules are retained through the combined structure of both holders rather than requiring complex openings in a single monolithic structure.
Solution Approach 2:
The retention function is merged into the assembled structure of upper and lower holders working together. The upper holder provides openings for battery insertion while the lower holder provides support surfaces, combining to achieve stable retention without requiring complex openings in both end and intermediate planes of a single piece.
2Reliability
If openings are formed with size matching battery module outside diameter to prevent gaps, then battery modules can be firmly retained, but manufacturing variation in battery diameter makes insertion difficult and assembly labor intensive
Solution Approach 1:
The lower holder is designed with elastic deformation capability, allowing it to flex during battery module insertion and then maintain firm retention. This dynamic flexibility accommodates manufacturing variations in battery diameter while ensuring stable retention after assembly.
Solution Approach 2:
The physical state of the lower holder changes from a rigid structure to an elastic deformable structure, allowing it to adapt to variations in battery module dimensions. This parameter change enables easy insertion while maintaining firm retention through elastic recovery.
3Reliability
If holder ribs project from inner surfaces to hold battery modules, then battery modules can be positioned in specified rows, but battery modules with non-straight connections cannot be securely held and warp under vibration
Solution Approach 1:
The lower holder functions as a flexible support structure that can elastically deform to accommodate battery modules with non-straight connections. This flexible support prevents warping and damage to the battery connection regions while maintaining positional stability, unlike rigid protruding ribs.
4Reliability
If openings are formed exactly the same shape as battery modules in both end and intermediate planes, then battery modules can be retained without movement, but the amount of trouble to insert and set battery modules increases significantly
Solution Approach 1:
The holder is segmented into upper and lower parts with different functions. The upper holder provides insertion openings while the lower holder provides support, allowing batteries to be inserted more easily without requiring precise openings in multiple planes of a single structure.
Solution Approach 2:
The lower holder's elastic deformation capability allows for easier insertion of battery modules while maintaining stable retention. This dynamic flexibility reduces assembly difficulty and time compared to rigid precise openings.
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
The solution effectively reduces battery module warp and deformation due to vibration, ensures secure retention of battery connections, and simplifies assembly, while providing efficient cooling through established gaps, thereby reducing manufacturing and operational costs.
Implementation Method 1
The solution effectively reduces battery module warp and deformation due to vibration
Implementation Method 2
a flexibly deforming cylindrical element, which is a elastomer cylinder 3
Implementation Method 3
providing efficient cooling through established gaps
Data Source
AI summary
The car power source battery apparatus houses a plurality of battery modules in a holder case. Battery modules have batteries connected in a straight-line fashion, and boundary regions between batteries are covered with elastomer cylinders, which can flexibly deform. The outline of elastomer cylinder regions of a battery module is wider than the outline of battery regions not covered by elastomer cylinders. The holder case is divided into a first holder and a second holder to form holding compartments to retain battery modules. The inside shape of a holding compartment is a cylinder shape which is narrower than the outline of elastomer cylinder regions and wider than the outline of battery regions. Elastomer cylinder regions are resiliently compressed by holding compartment inside surfaces to hold battery modules, and cooling gaps are established between battery regions and holding compartment inside surfaces.