Snapped Battery Enclosure Floor for Flatness and Sealed Cooling

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Solution Overview

Problem

Existing battery holder systems face challenges in maintaining flatness and absorbing impact energy while preventing distortion due to heat input during welding, and they often require dedicated dimensions and insufficient heat exchange capabilities.

Innovation Solution

A battery holder design featuring a floor with interlocking profiles that can transition between separate, snapped, and locking configurations, using male and female locking members with an interlocking and sealing agent to control flatness and absorb impact, allowing for modular adjustment and reduced heat input during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to assemble profiles during manufacturing, then the profiles are securely joined together, but heat input causes distortion in the floor which deteriorates flatness

Engineering Contradiction:

Improveprofile joining strengthVSAvoidfloor flatness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the thermal welding process with a mechanical interlocking system using male and female locking members. The male locking member engages with the female locking member through a snap-fit mechanism, providing secure joining without thermal input that would cause distortion. This mechanical substitution maintains profile connection strength while preserving floor flatness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the joining parameter from thermal (welding temperature) to mechanical (locking force and engagement geometry). By using a snap-fit mechanism with defined engagement forces and geometric constraints, the system achieves secure profile joining without the heat-induced distortion that compromises flatness.

Inventive Principle:

Principle #35Parameter changes

2Strength

If traditional rigid floor structures are used, then structural strength is maintained, but impact energy absorption is insufficient

Engineering Contradiction:

Improvestructural strengthVSAvoidimpact energy absorption

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The patent introduces dynamic characteristics to the floor structure through the snap-fit locking mechanism. The male and female locking members allow controlled movement and deformation during impact events, enabling the structure to absorb impact energy through elastic deformation and friction, while maintaining structural integrity through the interlocking geometry.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent employs a floor structure with controlled flexibility through the snap-fit connection system. The locking members allow slight movements and deformations that enable energy absorption during impact, while the interlocking mechanism maintains overall structural strength and prevents catastrophic failure.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If dedicated dimensions are provided for different battery types, then specific battery requirements are met, but device complexity and manufacturing variety increase

Engineering Contradiction:

Improvebattery type compatibilityVSAvoidholder configuration variety

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent creates a universal floor structure with standardized male and female locking members that can accommodate different battery types and configurations. The modular snap-fit system allows the same basic structure to be adapted to various dimensions and layouts by simply reconfiguring the locking members, eliminating the need for entirely different dedicated designs for each battery type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent divides the floor into modular segments with standardized locking interfaces. This segmentation allows different combinations and configurations of the same basic modules to serve various battery types, reducing overall device complexity while maintaining adaptability through combinatorial arrangements.

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If tight tolerance requirements are imposed on floor flatness, then battery support precision is improved, but manufacturing difficulty and cost increase

Engineering Contradiction:

Improvefloor flatness toleranceVSAvoidassembly difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces precision machining and welding operations with a mechanical snap-fit locking system. The male and female locking members provide self-aligning and self-locating features that inherently maintain flatness tolerances through their geometric design, eliminating the need for high-precision manufacturing while simplifying assembly operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20230344062A1High flatness snapped-in and sealed bottom floor for battery enclosures encompassing an integrated cooling system

Publication Date: 2023.10.26 CONSTELLIUM SINGEN GMBH

AI summary

The invention relates to a battery holder (1) comprising a floor (100) and a frame (200) delimiting a housing intended to receive all or part of a battery.The floor (100) comprises a plurality of profiles provided with male locking members (142) and female locking members (122).The floor (100) varies between:a separate configuration in which the profiles are separated;a snapped configuration in which the male locking members (142) and the female locking members (122) cooperate with each other to oppose a return to the separate configuration and are also movable relative to each other according to a predetermined degree of freedom;a locking configuration in which an interlocking and sealing agent (130) is interposed between the male locking members (142) the female locking members (122) and removes (irreversibly) said degree of freedom.