Integrated Fastener Assembly for Battery Pack Space Optimization
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Solution Overview
Problem
High voltage battery packs in automotive vehicles face packaging constraints, requiring additional space for locators and attachment features that increase the width and height of the battery pack assembly, limiting energy density and tool clearance.
Innovation Solution
A fastener assembly that combines a stud with a nut and cap, where the nut is either rotationally fixed or pivotable, acting as both a locator pin and mounting nut, allowing for off-center fastener accommodation and reducing the need for external mounting brackets, thereby minimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate locator pins and mounting brackets are used for battery pack assembly, then positioning accuracy and assembly reliability are improved, but the horizontal and vertical dimensions of the battery pack assembly increase
Solution Approach 1:
The patent combines the locator pin and mounting nut into a single integrated fastener assembly. The stud serves as the locator pin that extends into the mounting bore, while the nut is integrated into the stud body, eliminating the need for separate mounting brackets and reducing horizontal space requirements.
Solution Approach 2:
The integrated fastener assembly performs multiple functions: the stud portion acts as a locator pin for positioning accuracy, while the integrated nut provides the mounting function. This multi-functional design replaces what previously required separate components, reducing overall assembly dimensions.
2Measurement precision
If separate locator pins and mounting brackets are used, then positioning accuracy is improved, but the vertical dimension of the battery pack assembly increases
Solution Approach 1:
The locator pin and mounting nut are merged into a single vertical integration. The stud extends vertically into the mounting bore to provide positioning accuracy, while the nut is integrated into the stud body rather than requiring a separate horizontal mounting bracket, thus reducing vertical dimension.
3Reliability
If a rotationally fixed nut is used in the fastener assembly, then assembly robustness is improved, but adaptability to off-center fasteners is reduced
Solution Approach 1:
The patent provides two embodiments: one with a rotationally fixed nut (achieved through tang-slot engagement) for high robustness applications, and another with a pivotable nut (when cavity volume exceeds nut volume) that can adapt to off-center fasteners. This dynamic design choice allows optimization based on specific application requirements.
4Adaptability or versatility
If the nut is pivotable relative to the central axis, then adaptability to off-center fasteners is improved, but assembly robustness is reduced
Solution Approach 1:
When the cavity internal volume is greater than the nut volume, the nut is allowed to pivot relative to the central axis. This dynamic capability enables accommodation of off-center fasteners, though it reduces the rotational constraint that would otherwise provide maximum assembly robustness.
Data Source
AI summary
A fastener assembly includes a stud and a nut. The stud has a proximal end and a distal end with a body therebetween. The stud also has a central axis extending from the proximal end to the distal end. The proximal end has a flange for coupling to a surface. The body has a cavity opening to an orifice at the distal end. The nut is retained within the cavity. Rotation of the nut about the central axis is inhibited.