Snap-Fit End Plate Assembly for Battery Cell Stack Compression
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Solution Overview
Problem
Conventional battery cell stack assembly methods are cumbersome and prone to errors, often resulting in suboptimal compression due to pre-tension loss and complex fixation processes like welding or screwing.
Innovation Solution
A battery system with a cell stack frame featuring interlocking end plates and frame walls that establish a snap-fit connection, allowing for simplified assembly and consistent compression without pre-compression, using cantilever snap-fit elements for secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pre-compression is applied to the cell stack before insertion, then the cell stack can be inserted into the cavity, but the pre-tension is lost when the insertion clamp is released and compression level is suboptimal
Solution Approach 1:
The end plate is pre-configured with interlocking elements that engage with the frame walls to automatically maintain compression force on the cell stack, eliminating the need for pre-compression and subsequent tension loss
Solution Approach 2:
The mechanical insertion clamp system is replaced with a snap-fit interlocking mechanism between the end plate and frame walls, which maintains compression without requiring pre-tension or complex clamping operations
2Reliability
If welding or screwing is used to fix the end plate, then the end plate can be securely attached, but the assembly process becomes time consuming and prone to error
Solution Approach 1:
The end plate automatically attaches to the frame walls through self-aligning interlocking elements that snap into place without requiring external fastening operations, making the assembly process simple and error-proof
Solution Approach 2:
The complex fastening operations (welding, screwing) are extracted and replaced with a simple snap-fit mechanism, removing the time-consuming and error-prone steps while maintaining secure attachment
3Force
If the end plate is fixed to side walls, then the end plate can exert pressure on the cell stack, but the fixation process is complex and difficult to place correctly
Solution Approach 1:
The end plate self-aligns and self-fixes to the frame walls through complementary interlocking elements, automatically ensuring correct placement and eliminating the complexity of manual positioning and fixation
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
Ensures efficient and reliable compression of the cell stack through a snap-fit mechanism, simplifying assembly and reducing the risk of errors, while maintaining optimal pressure on battery cells.
Implementation Method 1
The end plate includes first interlocking elements at opposite lateral sides of the end plate, the first interlocking elements being configured to interlock with second interlocking elements of the frame walls in a fixture position of the end plate for establishing a snap fit connection
Data Source
AI summary
A battery system including: a cell stack including a plurality of battery cells arranged along a stacking axis; and a cell stack frame accommodating the cell stack. The cell stack frame includes frame walls and an end plate, and the frame walls include second interlocking elements. The end plate includes: first interlocking elements at opposite lateral sides of the end plate, the first interlocking elements being configured to interlock with the second interlocking elements of the frame walls in a fixture position of the end plate and for establishing a snap fit connection between the end plate and the frame walls such that the end plate exerts pressure onto the cell stack; a plate element facing the cell stack that, in the fixture position, exerts pressure onto the cell stack; and lateral wall elements extending from the plate element in a direction away from the cell stack.