Prismatic Cell Frame With Polymer Compression Limiter
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Solution Overview
Problem
The existing prismatic repeating frame assemblies for battery packs face challenges in maintaining structural integrity under operational loads and thermal expansion, often requiring metallic compression limiters that introduce debris and complexity, and are not environmentally friendly.
Innovation Solution
A prismatic repeating frame assembly using a base polymer with an engineered polymer compression limiter, co-injected to provide structural support and anti-compressive resistance, eliminating the need for heat insertion and metallic components, thus enhancing cleanliness and reducing assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic compression limiters are used to maintain structural integrity under compression loads, then the structural strength is improved, but debris contamination and assembly complexity increase
Solution Approach 1:
The patent removes the metallic compression limiter component entirely from the assembly, extracting the source of debris contamination while maintaining compression functionality through the plastic frame's inherent structural design
Solution Approach 2:
The plastic frame assembly is designed to perform its own compression function without requiring separate metallic limiters, with the frame structure itself providing the necessary structural integrity and compression resistance
2Force
If metallic compression limiters are used to withstand compression loads, then the load-bearing capacity is improved, but assembly complexity and manufacturing steps increase
Solution Approach 1:
The compression limiter function is merged into the frame assembly itself, with the plastic frame structure integrating the load-bearing capacity that previously required separate metallic components
Solution Approach 2:
The patent uses engineered plastic materials with enhanced mechanical properties to achieve the load-bearing capacity of metallic limiters, utilizing composite material properties to replace metal components
3Strength
If heat insertion process is used to install metallic compression limiters, then the structural integrity is improved, but production cycle time increases
Solution Approach 1:
The heat insertion process is removed from the manufacturing workflow by eliminating the metallic compression limiter component, allowing for faster assembly without thermal processing steps
Solution Approach 2:
The compression and structural reinforcement are built into the frame assembly during the molding process itself, rather than requiring post-assembly heat insertion steps
4Reliability
If metallic compression limiters are used to maintain structural integrity, then the reliability is improved, but environmental impact increases
Solution Approach 1:
The material composition parameter is changed from metallic to engineered plastic, maintaining structural integrity while improving environmental compatibility and recyclability
Solution Approach 2:
The patent employs engineered plastic materials with enhanced mechanical properties to replace metallic limiters, achieving comparable reliability with reduced environmental impact
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
The solution effectively maintains structural integrity while reducing contamination, assembly complexity, and environmental impact, with improved production cycle times and reduced mass, using polymers that withstand operational forces and thermal expansion without the need for metallic components.
Implementation Method 1
the engineered polymer that is resistant to the loads and forces exerted by the assembly process, as well as the frequency inputs from a vehicle in operation, creep, and thermal expansion
Implementation Method 2
the engineered polymer that is resistant to the loads and forces exerted by the assembly process, as well as the frequency inputs from a vehicle in operation, creep, and thermal expansion
Data Source
AI summary
A prismatic repeating frame assembly for a battery pack includes a main body and a hollow compression limiter. The main body is formed from a first polymer. The main body has an aperture formed therein. The hollow compression limiter is formed from a second polymer. The compression limiter is disposed in the aperture of the main body and permits a compression rod to be disposed therethrough. The second polymer is configured to withstand forces during an assembly of the battery pack and frequency inputs during an operation of the battery pack.