Molded Insert for EV Battery Pack Assembly
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Solution Overview
Problem
The manufacturing of electric vehicle battery packs faces challenges in ensuring reliable electrical connections, efficient cooling, and cost-effective assembly, particularly due to the need for rapid solidification of molded inserts to accommodate thousands of individual battery cells and a coolant loop within a limited time frame.
Innovation Solution
The method involves using an injection mold to arrange battery cells in rows and route a coolant loop around them, followed by injection molding a molded insert that encompasses both, using materials that solidify quickly, such as plastics or epoxies, to fix the cells and coolant loop relative to each other, while leaving exposed terminals for electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing processes are used to assemble battery cells and coolant loops, then assembly reliability may be maintained, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent combines the battery cell assembly, coolant loop routing, and structural housing into a single integrated molded insert. This merging of multiple components into one piece eliminates separate assembly steps for securing coolant loops to battery cells and reduces the number of fastening operations required, directly addressing the productivity challenge while maintaining assembly reliability.
Solution Approach 2:
The molded insert is prepared in advance with pre-formed coolant loop routing channels and mounting features integrated into its structure. This preliminary action of pre-configuring the insert with all necessary coolant pathways and attachment points eliminates the need for on-site routing and securing operations, significantly reducing manufacturing time while ensuring consistent, reliable assembly.
2Productivity
If molded inserts use materials with long solidification times, then material strength may be sufficient, but manufacturing productivity decreases
Solution Approach 1:
The patent specifies using thermoplastics with melt flow rates of at least 10 g/10 min, which is a parameter change that enables faster injection molding and quicker solidification. This parameter optimization allows the molded insert to achieve sufficient structural strength in under 10 minutes, directly resolving the contradiction between rapid solidification and adequate strength for withstanding vehicle use conditions.
Solution Approach 2:
The molded insert can incorporate fiber reinforcements or blended polymer compositions that provide high strength-to-weight ratios and rapid solidification characteristics. These composite material solutions enable the insert to achieve the required mechanical strength for securing battery cells and coolant loops while maintaining the fast solidification time needed for high-volume manufacturing productivity.
3Ease of repair
If battery packs are designed for easy replacement, then serviceability improves, but manufacturing complexity increases
Solution Approach 1:
The patent creates a self-contained modular battery pack unit where the molded insert with integrated coolant loops and battery cell assemblies functions as a replaceable module. This segmentation isolates the complex integrated insert as a discrete unit that can be removed and replaced without affecting other vehicle systems, improving serviceability while managing manufacturing complexity through standardized modular design.
Solution Approach 2:
The molded insert serves multiple functions simultaneously: it provides structural housing, routes coolant loops, secures battery cells, and enables modular replacement. This multi-functionality consolidates what would otherwise require separate components and assembly steps into a single universal unit, improving ease of repair through simple module replacement while the standardized design actually reduces long-term manufacturing complexity.
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 approach significantly reduces manufacturing time and cost by allowing the molded insert to solidify in under 10 minutes, forming a reliable and efficient battery pack that can withstand vehicle use and be easily installed or replaced.
Implementation Method 1
injection molding a molded insert that encompasses the plurality of cells and the coolant loop
Implementation Method 2
The molded insert may require less than 10 minutes to solidify after the molded insert is injection molded
Data Source
AI summary
A battery pack for an electric vehicle may include a plurality of battery cells arranged in on or more rows, a coolant loop, and a molded insert that encompasses the plurality of cells and the coolant loop such that the plurality of cells and the coolant loop are fixed relative to each other. The molded insert may cover a large portion of the coolant loop and/or the individual battery cells of the battery pack. An injection mold can be used as a fixture to hold the individual battery cells in place relative to the coolant loop, and the molded insert can be injected around the battery and coolant loop assembly.