Ratcheting Battery Frame Retention for Consistent Clamping
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Solution Overview
Problem
Conventional battery packs for electrified vehicles face challenges due to inconsistent clamping forces from support structures, leading to varying cell stack dimensions and packaging issues.
Innovation Solution
The use of array frames with a ratchet feature that mates with a column bolt to secure the battery cells, ensuring consistent clamping forces and stable assembly through a 'zip-tie' effect, where the ratchet feature restricts movement of the array frames relative to the column bolt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional support structures are used to retain battery cells, then the battery pack can be assembled, but the clamping forces on battery cells are inconsistent, resulting in varying cell stack dimensions and packaging challenges
Solution Approach 1:
The support structure incorporates a ratchet mechanism that allows dynamic adjustment of clamping forces. The ratchet feature enables the support structure to adapt to varying battery cell dimensions while maintaining consistent clamping force, resolving the contradiction between manufacturing precision and reliability by allowing the system to dynamically compensate for dimensional variations.
Solution Approach 2:
The invention changes the clamping force parameter from fixed to variable through the ratchet mechanism. By allowing incremental adjustments in clamping force, the system can maintain optimal pressure on battery cells despite variations in cell stack dimensions, thereby improving both manufacturing precision and reliability simultaneously.
2Reliability
If array frames are secured together without a ratchet mechanism, then the assembly is simpler, but relative movement between frames occurs, reducing assembly robustness and increasing separation under vibration
Solution Approach 1:
The ratchet mechanism provides a dynamic locking system that allows for easy assembly and disassembly while maintaining secure connection during operation. The one-way engagement feature enables simple installation but prevents relative movement under vibration, resolving the contradiction between assembly robustness and device complexity by providing security only when needed.
Solution Approach 2:
The ratchet feature acts as an intermediary between the array frames and column bolts, translating simple bolt insertion into a secure, multi-position locked connection. This intermediary mechanism provides robust anti-vibration performance without requiring complex fastening procedures, thereby improving reliability while keeping the fastening process relatively simple.
3Productivity
If multiple array frames are stacked without individual securing, then assembly is faster, but relative movement between frames reduces vibration resistance and durability
Solution Approach 1:
The invention segments the securing function by providing individual ratchet features on each array frame that can engage with column bolts independently. This allows frames to be stacked and secured in a systematic manner that maintains assembly speed while ensuring each frame is individually protected against vibration-induced movement, resolving the contradiction between productivity and vibration resistance.
Solution Approach 2:
The ratchet mechanism provides dynamic securing that allows rapid assembly through simple engagement but automatically prevents relative movement when vibration forces are applied. The mechanism transitions from a simple insertion action to a locked state, providing vibration resistance without significantly impacting assembly speed.
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 solution enhances the robustness of the battery assembly by locking the frames in position, reducing relative separation and improving vibration characteristics, thereby increasing durability and consistency in cell stack dimensions.
Implementation Method 1
each of the plurality of array frames includes a ratchet feature. A column bolt includes a raised surface configured to mate with the ratchet feature of each of the plurality of array frames to secure the plurality of array frames together
Implementation Method 2
the ratchet feature is established by a protruding wall of a fastening band of at least one of the plurality of array frames. the first lip and the second lip abut against the raised surface of the column bolt to restrict movement of the plurality of array frames relative to the column bolt
Data Source
AI summary
A battery pack includes a grouping of battery cells and a plurality of array frames for retaining the grouping of battery cells. Each of the plurality of array frames includes a ratchet feature. A column bolt includes a raised surface configured to mate with the ratchet feature of each of the plurality of array frames to secure the plurality of array frames together.