Lipped Retention Member for Battery Array Stability
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Solution Overview
Problem
Existing traction battery packs face challenges in securely retaining battery arrays within enclosures, particularly due to the need for effective retention mechanisms that ensure stability and structural integrity while minimizing complexity and cost.
Innovation Solution
The use of an extruded retention member with a lip, which extends axially alongside the battery cell frames and is secured directly to endplates, along with mechanical fasteners and tensioning rods, to hold the battery cell frames between the lip and the enclosure floor, providing a secure and cost-effective retention solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional retention mechanisms are used to secure battery arrays, then reliability is improved, but device complexity increases
Solution Approach 1:
The retention member integrates multiple functions into a single component: it provides retention through the lip structure, structural support through the extruded body, and mounting attachment through the bore. This consolidation eliminates the need for separate retention brackets, support structures, and mounting hardware, thereby reducing device complexity while maintaining reliability
Solution Approach 2:
The retention member serves multiple purposes simultaneously: it acts as a retention element via the lip, a structural support element through its extruded body, and a mounting element via the bore for fasteners. This multi-functionality reduces the number of components needed in the battery array retention system
2Strength
If multiple retention components are used to ensure structural integrity, then strength is improved, but device complexity increases
Solution Approach 1:
The retention member combines retention, support, and mounting functions into one integrated component, eliminating the need for multiple separate parts while maintaining the structural integrity required for secure battery array retention
3Device complexity
If simplified retention mechanisms are used, then device complexity is reduced, but reliability deteriorates
Solution Approach 1:
The integrated retention member maintains reliability by incorporating all necessary retention features (lip, body, bore) into a single robust component that provides secure retention while simplifying the overall system
Solution Approach 2:
The extruded retention member utilizes its geometric shape and curvature to provide structural strength and retention capability, allowing a simplified design to achieve reliable retention through intelligent use of form rather than complex assembly
Data Source
AI summary
A battery assembly includes, among other things, an enclosure having a floor, and battery cell frames disposed along an axis within the enclosure. Each of the battery cell frames includes a frame foot that projects laterally outward. An endplate is at an axial end of the battery cell frames. The endplate includes an endplate retention flange that projects laterally outward to laterally overlap with a portion of the retention member. A retention member extends axially alongside the battery cell frames. The retention member includes a lip that projects laterally inward across the frame feet such that the frame feet are held between the lip and the floor. An axial end portion of the retention member is secured directly to the endplate retention flange.