Flexible-Rigid Retention Clip for EV Battery Array Assembly
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Solution Overview
Problem
Existing battery array designs for electrified vehicles face challenges in securely mounting and retaining multiple battery cells within the battery assembly, particularly in arresting movement and ensuring effective heat management and assembly efficiency.
Innovation Solution
The design incorporates a tray with an array frame and a retention clip system, where one component is flexible and the other is rigid, allowing for secure engagement and retention of the battery array, utilizing undulated clip arms and thermal fins for heat management, and features like recessed grooves and lifting arms for assembly and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional rigid retention methods are used to secure battery cells, then structural stability is improved, but assembly complexity and difficulty increase
Solution Approach 1:
The retention clip incorporates a flexible portion that can dynamically change its rigidity state. During assembly, the flexible portion allows easy engagement with battery cells, and during operation, it provides rigid retention to secure cells against vibration and movement. This dynamic adaptation resolves the contradiction between structural stability and assembly complexity.
Solution Approach 2:
The retention clip changes its physical parameter (rigidity) based on operational requirements. The flexible portion transitions from a compliant state during assembly to a rigid state during operation, enabling the same component to satisfy both assembly ease and structural stability requirements without increasing overall device complexity.
2Reliability
If multiple separate retention components are used to secure battery cells, then retention reliability is improved, but device complexity increases
Solution Approach 1:
The retention clip merges multiple functions into a single integrated component. It combines retention, positioning, and securing functions that would traditionally require multiple separate components. The single clip structure with its flexible portion and engagement features provides reliable battery cell retention while reducing assembly complexity and the number of parts.
3Ease of manufacture
If flexible retention components are used to simplify assembly, then ease of assembly is improved, but structural stability deteriorates
Solution Approach 1:
The retention clip incorporates a flexible portion that can dynamically change its rigidity state. During assembly, the flexible portion allows easy engagement with battery cells, and during operation, it provides rigid retention to secure cells against vibration and movement. This dynamic adaptation resolves the contradiction between structural stability and assembly complexity.
Solution Approach 2:
The retention clip changes its physical parameter (rigidity) based on operational requirements. The flexible portion transitions from a compliant state during assembly to a rigid state during operation, enabling the same component to satisfy both assembly ease and structural stability requirements without increasing overall device complexity.
Data Source
AI summary
A battery pack includes a tray, an array frame positioned relative to the tray and that houses at least one battery cell, and a retention clip mounted to the tray and engageable with a portion of the array frame. The portion or the retention clip is flexible and the other of the portion and the retention clip is rigid.