Slim Battery Tray Self-Aligning Docking Mechanism
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Solution Overview
Problem
Existing battery assemblies face challenges in optimizing space utilization and alignment of unit cells, leading to suboptimal accumulation capacities and voltages, as they are often designed based on the battery tray size rather than cell size.
Innovation Solution
A self-aligning system is implemented using inverted-V or inverted-U shaped docking recesses on the unit cells that match with counterpart formations on a slim U-shaped tray, allowing cells to self-assemble and align properly, thereby optimizing their positioning and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery assemblies are designed based on battery tray size rather than cell size, then the overall dimensions can be controlled, but space utilization and accumulation capacities become suboptimal
Solution Approach 1:
The patent inverts the conventional design approach by specifying cell dimensions first and then designing the tray to accommodate them, rather than designing the tray first and forcing cells to fit. This inversion allows optimal space utilization and accumulation capacities while maintaining controlled overall dimensions through the self-aligning docking system.
2Manufacturing precision
If conventional battery trays are used without self-aligning features, then manufacturing is simpler, but cell alignment and positioning are suboptimal
Solution Approach 1:
The tray incorporates self-aligning docking features (recesses and protrusions) that enable cells to automatically align themselves during assembly without requiring complex external alignment mechanisms. This self-service alignment system achieves high manufacturing precision while maintaining relative simplicity in the manufacturing process.
Solution Approach 2:
The docking features act as intermediary elements between the cells and the tray, facilitating precise alignment and positioning. The inverted-V or inverted-U shaped recesses in the tray bottom work with corresponding protrusions on cell bottoms to create accurate alignment without requiring complex manufacturing processes.
3Ease of operation
If cells are allowed to self-align through docking recesses, then assembly is easier and more precise, but the tray structure becomes more complex
Solution Approach 1:
The tray bottom is segmented into multiple docking recesses (inverted-V or inverted-U shaped) distributed along its length, each providing localized alignment functionality. This segmentation allows the complex alignment function to be distributed across simple, repetitive geometric features rather than requiring a single complex mechanism.
Data Source
AI summary
A battery assembly (10) has a series of rectangular cells (20) and a square-U shaped tray (14) to support the cells (20) in series, with bottoms (24) coplanar and adjacent sides parallel. The tray (14) has spaced arms (43) for opposing the endmost ones of the series of cells (12) interconnected by a rigid web (41) that provides a generally flat seating surface for the cell bottoms (24). The web (41) has longitudinal tracks (49) which raise above the seating surface of the wen (41) and which extend beneath all the cell bottoms (24). The cell bottoms (24) have counterpart longitudinal channels (52) for self-assembling with the tracks (49) of the web (41) and provide properly aligned seating of the cell bottoms (24) by disallowing lateral displacement but allowing longitudinal sliding order to form as dense as a single-file line-up (12) as possible. The tracks (49) also serve to stiffen the web (41) against sagging or twisting.