Battery Module End Plate With Integrated Electrode Base Molding
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Solution Overview
Problem
The existing assembly methods for battery end plates result in multiple interfaces and gaps, leading to high manufacturing costs, potential loosening of components, and an inferior appearance due to separate manufacturing and plug-connection of the base and end plate components.
Innovation Solution
An end plate design incorporating a separation portion that allows for injection-molding of the base material, eliminating assembly interfaces and gaps, and ensuring a tight connection between the base and main body portion, while maintaining an excellent appearance by preventing material overflow during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base and main body portion are manufactured separately and assembled through plug-connection, then the manufacturing flexibility is improved, but the assembly interface complexity increases and gaps appear between components
Solution Approach 1:
The base and main body portion are merged into a single integrated component manufactured through injection-molding. The separation portion is embedded within the main body portion during the same molding process, eliminating the need for separate manufacturing and assembly of these components. This resolves the technical contradiction by maintaining manufacturing efficiency while eliminating assembly interface complexity and gaps.
2Ease of operation
If the base and main body portion are assembled through plug-connection, then the assembly process is simplified, but the bonding strength decreases and components may loosen
Solution Approach 1:
The base and main body portion are combined into a single integrally molded component, eliminating the plug-connection assembly process entirely. This resolves the contradiction by achieving both strong bonding (through integral construction) and assembly simplicity (through single-step molding).
Solution Approach 2:
The separation portion is pre-positioned within the main body portion during the injection-molding process before the base material is formed. This preliminary placement ensures proper positioning and strong bonding without requiring subsequent assembly operations, resolving the contradiction between assembly simplicity and bonding strength.
3Ease of manufacture
If the base material is injection-molded without a separation portion, then the manufacturing process is simplified, but the material overflows to positions below the separation portion causing poor appearance
Solution Approach 1:
The separation portion divides the injection-molding cavity into distinct regions, preventing base material from overflowing into areas that would compromise appearance. This segmentation allows the molding process to remain simple while achieving precise material placement and excellent surface finish.
Solution Approach 2:
The separation portion acts as an intermediary barrier between the injection-molding cavity and the final product surface. It controls material flow during molding, preventing overflow while maintaining process simplicity, thus resolving the contradiction between manufacturing simplicity and appearance quality.
4Adaptability or versatility
If multiple assembly interfaces are used to connect base components, then the adaptability is improved, but the production time increases and labor costs rise
Solution Approach 1:
Multiple components that would require multiple assembly interfaces are merged into a single integrally molded part. This eliminates sequential assembly operations, significantly improving production efficiency while reducing labor costs. The adaptability is maintained through the functional integration of these components within the single part structure.
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 design reduces manufacturing costs, enhances bonding strength, and ensures a smooth, burr-free appearance by integrating the output electrode base into the end plate, eliminating the need for separate component assembly and minimizing labor costs.
Implementation Method 1
under a blocking action of the separation portion, a material for making the base can be connected to the main body portion through injection-molding
Data Source
AI summary
An end plate includes a main body portion arranged at one end of the battery module and configured to fix a battery cell in the battery module, a base configured to fix an output electrode of the battery module, and a separation portion located in the main body portion and configured to separate the main body portion from the base.